www.apc.com Design Guide 2009 Design Guide UPS Protection Systems TGBT CS N PFC TNC Q3BP L2 Filtres CEM RESEAU 2 PEN TNC L1 Ond TGBT L3 CSR2 CS NNEUTRE Q4S TNC PFC Ond Li_R2 TT alim PEN +Vbatt CS C7 R7 C8 R8 F9 C9 R9 Vdc_pos alim TGBT F7 F8 TI coup TN1 comp DC alim LE2 LE1 PEN PE TNS C1 LEM1 LEM6 Vi_Ond Li_F_Ond LS1 TI5 TI4 C4 LEM7 LEM2 F2 DJ Batt LN LS2 TI1 F4 R1 TI6 TI2 F5 LEM5 C5 LEM8 LS3 TI3 F6 TI7 LEM3 F3 LEM4/4' Filtres CEM mise en // Ond K2 F1 RESEAU 1 +15/-15V + mesure K1 Q1 C1 C2 C3 C6 LB1 CS ond C2 LB2 -Vbatt u_res1 R2 Filtres CEM PFC UTILISATION N alim TNC RCR2 autoalimCS Imut LEM TN2 Neutre Q5N u_ctrl_1 cde CS ond Li_Util TI util alim Vdc_neg Filtrage courant PFC Précharge capas DC PFC Hacheur Batterie reversible Bras Neutre onduleur SCHEMA PROXIMA General contents Chapter 1 Key factors in UPS installations Introduction.........................................................................................1-2 Using this guide..................................................................................1-3 Overview of protection solutions......................................................1-4 UPSs in electrical installations .........................................................1-6 Basic notions on installations with UPSs........................................1-9 Power calculations .............................................................................1-17 Control of upstream harmonics ........................................................1-24 System earthing arrangements.........................................................1-30 Protection ............................................................................................1-35 Cables ..................................................................................................1-43 Energy storage....................................................................................1-45 Human-machine interface and communication ..............................1-49 Preliminary work.................................................................................1-51 Chapter 2 Selection of the UPS configuration Types of possible configurations .....................................................2-2 Selection table and corresponding ranges......................................2-5 Diagram no. 1 ......................................................................................2-6 Single UPS Diagram no. 2 ......................................................................................2-7 Active redundancy with two integrated parallel UPS units Diagram no. 3 ......................................................................................2-8 Active redundancy with integrated parallel UPS units and external maintenance bypass Diagram no. 4 ......................................................................................2-9 Isolated redundancy with two UPS units Diagram no. 5 ......................................................................................2-10 Active redundancy with parallel UPS units and centralised static-switch cubicle (SSC) Diagram no. 6 ......................................................................................2-11 Active redundancy with parallel UPS units, SSC and total isolation, single busbar Diagram no. 7 ......................................................................................2-12 Active redundancy with parallel UPS units, SSC and total isolation, double busbar Diagram no. 8 ......................................................................................2-13 Active redundancy with parallel UPS units, double SSC and total isolation, single busbar Diagram no. 9 ......................................................................................2-14 Active redundancy with parallel UPS units, double SSC and total isolation, double busbar Diagram no. 10 ....................................................................................2-15 Isolated redundancy with N+1 UPS units Diagram no. 11 ....................................................................................2-16 Redundant distribution with static transfer switch (STS) Diagram no. 12 ....................................................................................2-18 Redundant distribution with static transfer switch (STS) and PDU Chapter 3 Elimination of harmonics in installations Harmonics........................................................................... 3-2 Elimination of harmonics ...................................................... 3-11 MGETM SineWaveTM active harmonic conditioners ..................... 3-14 APC by Schneider Electric 05/2009 edition p. I Chapitre 4 APC by Schneider Electric ranges MGETM GalaxyTM 3500 UPSs ..............................................................4-4 MGETM GalaxyTM 5000 UPSs ..............................................................4-12 MGETM Galaxy PWTM UPSs .................................................................4-24 MGETM GalaxyTM 7000 UPSs ..............................................................4-32 MGETM GalaxyTM 9000 UPSs ..............................................................4-48 SymmetraTM PX 48 and PX 160 UPSs ...............................................4-60 SymmetraTM PX 250/500 UPSs...........................................................4-68 SymmetraTM MW UPSs .......................................................................4-75 MGETM SineWaveTM active harmonic conditioners..........................4-82 MGETMUpsilonTM STS statis transfer systems .................................4-86 Source synchronisation module.......................................................4-92 Chapter 5 Theoretical review Supplying sensitive loads .................................................................5-2 UPSs ....................................................................................................5-4 Types of UPSs.....................................................................................5-7 UPS components and operation .......................................................5-14 Electromagnetic compatibility (EMC) ...............................................5-26 UPS standards ....................................................................................5-28 Energy storage....................................................................................5-31 UPS / generator-set combination......................................................5-35 Transient load conditions..................................................................5-37 Harmonics ...........................................................................................5-38 Non-linear loads and PWM technology ............................................5-43 PFC rectifier ........................................................................................5-49 Chapter 6 Specifications guides (available on CD-ROM) Specification guide no. 1 (single/parallel MGE Galaxy 3500 UPS)...6-1 Single/parallel UPS system, 3-phase, 10 to 40/160 kVA Specification guide no. 2a (single MGE Galaxy 5000 UPS) .............6-2a Single-UPS unit, 3-phase, 40 to 120 kVA Specification guide no. 2b (parallel MGE Galaxy 5000 UPS)...........6-2b Parallel UPS system, 3-phase, 80 to 720 kVA Specification guide no. 3a (single MGE Galaxy PW) ........................6-3a Single-UPS unit, 3-phase, 160 to 200 kVA Specification guide no. 3b (parallel MGE Galaxy PW)......................6-3b Parallel UPS system, 3-phase, 320 to 800 kVA Specification guide no. 4a (single MGE Galaxy 7000)......................6-4a Single-UPS unit, 3-phase, 250 to 500 kVA Specification guide no. 4b (parallel MGE Galaxy 7000) ...................6-4b Parallel UPS system, 3-phase, 500 to 4000 kVA Specification guide no. 5a (single MGE Galaxy 9000)......................6-5a Single-UPS unit, 3-phase, 800 kVA Specification guide no. 5b (parallel MGE Galaxy 9000) ...................6-5b Parallel UPS system, 3-phase, 1600 to 4800 kVA Specification guide no. 6 (Symmetra PX 48/160) .............................6-6 Modular UPS, 3-phase, 16 to 48 kVA/160 kVA Specification guide no. 7 (Symmetra PX 250/500) ...........................6-7 Modular UPS, 3-phase, 25 to 500 kVA Specification guide no. 8 (Symmetra MW)........................................6-8 Scalable UPS, 3-phase, 400 to 1600/4000 kVA Specification guide no. 9 (MGE SineWave) ......................................6-9 Active harmonic conditioner, 20 to 480 A Specification guide no. 10 (MGE Upsilon STS) ................................6-10 Static transfer switch Chapter 7 Index, glossary, bibliography Index ....................................................................................................7-2 Glossary ..............................................................................................7-6 Bibliography........................................................................................7-14 APC by Schneider Electric 05/2009 edition p. II Chapter 1. Key factors in UPS installations Contents Introduction .....................................................................1-2 Using this guide ..............................................................1-3 Overview of protection solutions ..................................1-4 Protection solutions ..............................................................................1-4 Accompanying software and services ..................................................1-5 UPSs in electrical installations ......................................1-6 Function of each component in the installation.....................................1-6 Essential installation parameters..........................................................1-7 Sources of information in setting up installation specifications .............1-8 Basic notions on installations with UPSs .....................1-9 Need for high-quality and high-availability power .................................1-9 Supply systems with UPSs...................................................................1-10 UPS power quality................................................................................1-11 UPS power availability..........................................................................1-13 Selection of the configuration ...............................................................1-16 Power calculations..........................................................1-17 Elements required for power calculations.............................................1-17 Ratings of single-UPS configurations ...................................................1-19 Ratings of parallel-UPS configurations.................................................1-22 Control of upstream harmonics.....................................1-24 UPSs and upstream harmonic currents for different input rectifiers .....1-24 Filtering of upstream harmonics for Graetz bridge rectifiers .................1-25 Selection of a filter................................................................................1-27 System earthing arrangements......................................1-30 Background information on system earthing arrangements .................1-30 Applications in UPS installations ..........................................................1-32 Protection ........................................................................1-35 Protection using circuit breakers ..........................................................1-35 Selection of circuit breakers .................................................................1-38 Cables .............................................................................1-43 Selection of cable sizes........................................................................1-43 Example of an installation ....................................................................1-44 Energy storage ...............................................................1-45 Storage technologies............................................................................1-45 Selection of a battery............................................................................1-46 Battery monitoring ................................................................................1-47 Human-machine interface and communication ...........1-49 Human-machine interface (HMI) ..........................................................1-49 Communication ....................................................................................1-49 Preliminary work ............................................................1-51 Installation considerations ....................................................................1-51 Battery room.........................................................................................1-52 APC by Schneider Electric 05/2009 edition ch. 1 - p. 1 Introduction Growing needs for high-quality and high-availability power Problems related to the quality and availability of electrical power have become vitally important due to the key role of computers and electronics in the development of many critical applications. Disturbances in distribution systems (micro-outages, outages, voltage sags, etc.) can result in major losses or safety hazards in a number of activities such as: Sensitive process industries, where a malfunction in the control/monitoring systems can result in production losses. Airports and hospitals where faulty operation of equipment can represent a serious danger to human life. Information and communication technologies, where the necessary level of reliability and dependability is even higher. Data centers require high-quality, "nobreak" power 24/365, year after year and without halts for maintenance. UPS protection systems are now an integral part of the value chain of many companies. Their level of availability and power quality have a direct effect on the service continuity of operations. Productivity, the quality of products and services, the competitiveness of the company and site security depend on the smooth operation of the UPS. Failure is not an option. APC by Schneider Electric - a complete solution covering all needs APC by Schneider Electric offers a complete range of power-protection solutions to meet the needs of all sensitive applications. These solutions implement communicating software and products incorporating state-of-the-art technology offering the highest levels of reliability. They are backed by complete services based on unique expertise, worldwide presence and use of the TM most advanced techniques and technologies. APC Global Services , with 40 years of experience on customer sites, accompanies your installation throughout its life cycle, from design and start-up to operation and upgrades, wherever they may be. Uninterruptible power supplies (UPSs) are of course a central part of these solutions. They supply high-quality, high-availability continuous power with built-in, advanced communication interfaces that are compatible with both electrical and computer environments They are often used in conjunction with other communicating products such as active harmonic conditioners, transfer switches, distribution switchboards, batterymonitoring systems and supervision software. Taken as a whole, this offering provides a complete and effective answer to the protection problems that arise in sensitive installations. For data centers, on-demand solutions integrate the physical infrastructure including server racks, UPSs, electrical distribution, cooling and security along with the associated software. A guide to assist professionals dealing with electrical installations for critical applications APC by Schneider Electric has made a large part of its know-how available in this design guide. Its purpose is to assist in designing and installing complete, optimised powerprotection solutions, from the utility line through to the final load, corresponding to the quality and availability requirements of your critical applications. It is intended for all professionals dealing with this type of installation, including: Independent design offices and engineering firms, End-user design departments, Installers, Project managers, Facility managers, Computer system managers, Financial or purchasing managers. APC by Schneider Electric 05/2009 edition ch. 1 - p. 2 Using this guide Structure of this document Finding information Information may be located in a number of ways: The general contents at the start of the guide, The index in chapter 7, The overview on pages 4 and 5 of chapter 1, which presents the products, communication systems, software and services that are all part of protection solutions. Chapters Chapter 1 presents on pages 6 and 7 the role of UPSs in electrical installations and indicates the main parameters that must be taken into account. The remainder of the chapter guides you through the selection process for a solution by determining the main elements of an installation with a UPS. Chapter 2 presents a number of practical examples in view of selecting a configuration, from a simple, single-UPS unit through to installations offering exceptionally high levels of availability. Chapter 3 presents solutions to eliminate harmonic currents in installations. Chapter 4 presents the products and services offered by APC by Schneider Electric. Chapter 5 provides background technical information for devices and notions mentioned in other parts of the guide. Finally, to facilitate the preparation of projects: Chapter 6 contains typical technical-specification documents for different types of products and installations. Chapter 7 provides a glossary defining the main terms used in this guide and a list of standards and documents dealing with topics related to UPSs. Cross references The various chapters contain cross references (indicated by the symbol ) to other parts of the design guide presenting more in-depth information on specific topics. Refererences to technical articles (White Papers - WP) are indicated by the following symbol together with the number of the White Paper in question. See WP no. APC by Schneider Electric 05/2009 edition ch. 1 - p. 3 Overview of protection solutions Power protection solutions Fig. 1.1. APC by Schneider Electric products. APC by Schneider Electric 05/2009 edition ch. 1 p. 4 Overview of protection solutions Accompanying software and services Fig. 1.2. APC by Schneider Electric software and services. APC by Schneider Electric 05/2009 edition ch. 1 - p. 5 UPSs in electrical installations Function of each component in the installation Fig. 1.3. Functions of the components in installations with UPSs. APC by Schneider Electric 05/2009 edition ch. 1 - p. 6 UPSs in electrical installations (cont.) Essential installation parameters Fig. 1.4. Main parameters for the components in installations with UPSs. APC by Schneider Electric 05/2009 edition ch. 1 - p. 7 UPSs in electrical installations (cont.) Sources of information in setting up installation specifications The diagrams on the previous pages provide a general overview of the components and various parameters in installations with UPSs. It is now time to go into more detail. The table below indicates: ● the order in which the subjects are presented in this chapter ● the choices that must be made ● the purpose of each decision with the indication of the pages concerning the relevant elements in this chapter ● where additional information on each subject may be found in the other chapters of this design guide. Choices Mono or multisource architecture and configuration of UPS sources Purpose Determine the installation architecture and UPS configuration best suited to your requirements in terms of energy availability, upgrades, operation and budget. UPS power rating Determine the rating of the UPS unit or parallel units (for redundancy or capacity) required, taking into account the distribution-system and load characteristics. Reduce voltage distortion on the Control of upstream busbars to acceptable upstream levels, depending on the power harmonics sources likely to supply the UPS system. System earthing Ensure installation compliance with applicable standards for the protection arrangements of life and property and correct operation of devices. Which system earthing arrangements are required for which applications? Determine the breaking capacity and Upstream and the ratings of the circuit breakers downstream protection using upstream and downstream of the circuit breakers UPS, solve any discrimination problems. Limit voltage drops and temperature Connections rise in the cables, as well as harmonic distortion at the load inputs. Operation on battery power (backup Battery time) must last long enough to meet user requirements. Communication Define UPS communication with the electrical and computer environment. Preliminary work Construction work and ventilation must be planned, notably if there is a (if any) special battery room. Be aware of the main applicable UPS Standards standards. APC by Schneider Electric See Ch. 2 Additional information See Ch. 2 p. 5 Examples and comparison of 13 typical installations, from single-UPS units to high-availability architectures. Supplying sensitive loads. Ch. 5 p. 2 UPS configurations. Ch. 5 p. 23 Engine generator sets. Ch. 5 p. 35 Ch. 1 p. 17 UPS make-up and operation. Ch. 5 p. 14 Ch. 1 p. 24 Elimination of harmonics in installations. Harmonics Ch. 3 Ch. 5 p. 38 Ch. 1 p. 30 Ch. 1 p. 35 Ch. 1 p. 43 Ch. 1 p. 45 Energy-storage solutions and batteries. Ch. 5 p. 31 Ch. 1 p. 49 Ch. 5 p. 51 Ch. 5 p. 33 Electromagnetic compatibility GUIPR537UK - 01/2007 edition Ch. 5 p. 26 ch. 1 - p. 8 Basic notions on installations with UPSs Need for high-quality and high-availability power Disturbances in distribution-system power Public and private utilities supply electricity whose quality may be reduced by a number of disturbances. These disturbances are inevitable due to the distances involved and the wide variety of connected loads. The origin of disturbances includes: the distribution system itself (atmospheric conditions, accidents, switching of protection or control devices, etc.), user equipment (motors, disturbing devices such as arc furnaces, welding machines, systems incorporating power electronics, etc.). These disturbances include micro-outages, voltage sags, overvoltages, frequency variations, harmonics, HF noise, flicker, etc. through to extended outages. Disturbances in distribution-system power, see Ch. 5 p. 3. Requirements of sensitive loads Digital equipment (computers, telecom systems, instruments, etc.) use microprocessors that operate at frequencies of several mega or even giga Hertz, i.e. they carry out millions or even billions of operations per second. A disturbance in the electrical supply lasting just a few milliseconds can affect thousands or millions of basic operations. The result may be malfunctions and loss of data with dangerous (e.g. airports, hospitals) or costly consequences (e.g. loss of production). That is why many loads, called sensitive or critical loads, require a supply that is protected against distribution-system disturbances. Examples. industrial processes and their control/monitoring systems - risk of production losses. airports and hospitals - risks for the safety of people. information and communication technologies - risk of halts in processing at a very high hourly cost. Many manufacturers of sensitive equipment specify very strict tolerances (much stricter than those for the distribution system) for the supply of their equipment, one example being CBEMA (Computer Business Equipment Manufacturer’s Association) for computer equipment. Sensitive loads, see Ch. 5 p. 2 "Supply of sensitive loads". Costs incurred by the quality of electrical power Over 50% of failures for critical loads are due to the electrical supply and the hourly cost of downtime for the corresponding applications is generally very high (fig. 1.5). It is therefore vital for the modern economy, which is increasingly dependent on digital technologies, to solve the problems affecting the quality and the availability of the power supplied by the distribution system when it is intended for sensitive loads. 15 % 45 % Human error 20 % Supply problems Examples of hourly costs of failures ● mobile telephones - 40 kEuros. ● airline reservation systems - 90 kEuros. ● credit-card transactions - 2.5 MEuros. ● automotive assembly line - 6 MEuros ● stock-market transactions - 6.5 MEuros. Equipment failure 20 % Nuisance tripping (circuit breaker, etc.) Fig. 1.5. Origin and cost of system failures due to the electrical supply. APC by Schneider Electric 05/2009 edition ch. 1 - p. 9 Basic notions on installations with UPSs (cont.) Supply systems with UPSs Purpose of UPSs UPSs (uninterruptible power supply) are designed to meet the needs presented above. First launched in the 1970s, their importance has grown in step with the development of digital technologies. UPSs are electrical devices that are positioned between the distribution system and sensitive loads. They supply power that is much more reliable than the distribution system and corresponds to the needs of sensitive loads in terms of quality and availability. UPSs, see Ch. 5 p. 4 "The UPS solution". Types of UPSs The term UPS covers products with apparent power ratings from a few hundred VA up to several MVA, implementing different technologies. That is why standard IEC 62040-3 and its European equivalent ENV 62040-3 define three standard types (topologies) of UPS. UPS technologies include: Passive standby, Interaction with the distribution system, Double conversion. For the low power ratings (< 2 kVA), the three technologies coexist. For higher ratings, virtually all static UPSs (i.e. implementing semiconductor components, e.g. IGBTs) implement the double-conversion technology. Rotary UPSs (with rotating mechanical parts, e.g. flywheels) are not included in the standards and remain marginal on the market. Types of UPSs, see Ch. 5 p. 9 "Types of static UPSs". Double-conversion static UPSs This is virtually the only type of UPS used in high-power installations due to their unique advantages over the other types: complete regeneration of the power supplied at the output, total isolation of the load from the distribution system and its disturbances, no-break transfer (where applicable) to a bypass line. The operating principle (fig. 1.6) is presented below. during normal operation, a rectifier/charger turns the AC-input power into DC power to supply an inverter and float charge a battery. the inverter completely regenerates a sinusoidal signal, turning the DC power back into AC power that is free of all disturbances and within strict amplitude and frequency tolerances. if the AC-input power fails, the battery supplies the power required by the inverter for a specified backup time. a static bypass can transfer the load without a break in the supply of power to a bypass line to continue supplying the load if need be (internal fault, short-circuit downstream, maintenance). This "fault-tolerant" design makes it possible to continue supplying power to the load in "downgraded mode" (the power does not transit the inverter) during the time required to re-establish normal conditions. Double-conversion UPSs, see Ch. 5 p. 14 "Components and operation". Fig. 1.6. Double-conversion static UPS APC by Schneider Electric 05/2009 edition ch. 1 - p. 10 Basic notions on installations with UPSs (cont.) Power quality of UPSs Power quality of double-conversion UPSs By design, double-conversion solid-state UPSs supply to the connected loads a sinusoidal signal that is: high quality because it is continuously regenerated and regulated (amplitude 1%, frequency 0.5%), free of all disturbances from the distribution system (due to the double conversion) and in particular from micro-outages and outages (due to the battery). This level of quality must be ensured, whatever the type of load. Voltage quality for linear loads What is a linear load? A linear load supplied with a sinusoidal voltage draws a sinusoidal current having the same frequency as the voltage. The current may be displaced (angle ) with respect to the voltage (fig. 1.7). Examples of linear loads Many loads are linear, including standard light bulbs, heating units, resistive loads, motors, transformers, etc. They do not contain any active electronic components, only resistors (R), inductors (L) and capacitors (C). UPSs and linear loads For this type of load, the UPS output signal is very high quality, i.e. the voltage and current are perfectly sinusoidal, 50 or 60 Hz. Purely resistive load Fig. 1.7. Voltage and current for linear loads. Load with inductor and/or capacitor Voltage quality for non-linear loads What is a non-linear load? A non-linear (or distorting) load supplied with a sinusoidal voltage draws a periodic current that has the same frequency as the voltage, but is not sinusoidal. The current drawn by the load is in fact the combination (fig. 1.8) of: a sinusoidal current called the fundamental, at the 50 or 60 Hz frequency, harmonics, which are sinusoidal currents with an amplitude less than that of the fundamental, but a frequency that is a multiple of the fundamental and which defines the harmonic order (e.g. the third order harmonic has a frequency 3 x 50 Hz (or 60 Hz) and the fifth order harmonic has a frequency 5 x 50 Hz (or 60 Hz)). The harmonic currents are caused by the presence of power-electronic components (e.g. diodes, SCRs, IGBTs) which switch the input current. Examples of non-linear loads Non-linear loads include all those that have a switch-mode power supply at their input to supply the electronics (e.g. computers, variable-speed drives, etc.). Voltage and current drawn by a single-phase Effect of harmonics (H3 and H5 in this switch-mode power supply (computers). example). Fig. 1.8. The current drawn by non-linear loads is distorted by the harmonics. APC by Schneider Electric 05/2009 edition ch. 1 - p. 11 Basic notions on installations with UPSs (cont.) Harmonic spectrum of the current drawn by a non-linear load The harmonic analysis of a non-linear current consists in determining (fig. 1.9): the harmonic orders present in the current, the relative importance of each order, measured as the percentage of the order. rms value of harmonic k Hk% = distortion of harmonic k = rms value of the fundamental Voltage and current harmonic distortion Non-linear loads cause both current and voltage harmonics. This is because for each current harmonic, there is a voltage harmonic with the same frequency. The 50 Hz (or 60 Hz) sinusoidal voltage of the UPS is therefore distorted by the harmonics. The distortion of a sine wave is presented as a percentage: rms value of all the harmonic k THD* % = total distortion = rms value of the fundamental * Total Harmonic Distortion. The following values are defined: TDHU % for the voltage, based on the voltage harmonics, TDHI % for the current, based on the current harmonics (fig. 1.9). The higher the harmonic content, the greater the distortion. Practically speaking, the distortion in the current drawn by the load is much higher (THDI approximately 30%) than that of the voltage at the input (THDU approximately 5%). Harmonic distortion levels H5 = 33% H7 = 2.7% H11 = 7.3% H13 = 1.6% H17 = 2.6% H19 = 1.1% H23 = 1.5% H25 = 1.3% THDI = 35% (see calculation ch. 5, p. 41) Harmonic spectrum and corresponding THDI. Input current of a three-phase rectifier. Fig. 1.9. Example of the harmonic spectrum of the current drawn by a non-linear load. Non-linear loads, see Ch. 2 "Elimination of harmonics in installations" and Ch. 5 p. 38 "Harmonics". UPSs and non-linear loads Harmonics affect the sinusoidal voltage at the UPS output. Excessive distortion can disturb the linear loads connected in parallel on the output, notably by increasing the current they draw (temperature rise). To maintain the quality of the UPS output voltage, it is necessary to limit its distortion (THDU), i.e. limit the current harmonics that produce voltage distortion. In particular, it is necessary that the impedance (at the UPS output and in the cables supplying the load) remain low. Limiting the distortion of the output voltage Due to the free-frequency chopping technique employed, the impedance at the output of UPSs from APC by Schneider Electric is very low, whatever the frequency (i.e. whatever the harmonic order). This technique virtually eliminates all distortion in the output voltage when supplying non-linear loads. The quality of the output voltage is thus constant, even for non-linear loads. Practically speaking, installation designers must: check UPS output values for non-linear loads and, in particular, make sure that the announced level of distortion, measured for standardised non-linear loads as per standard IEC 62040-3, is very low (THDU < 2 to 3%), limit the length (impedance) of the output cables supplying the loads. UPS performance for non-linear loads, see Ch. 5 p. 43. APC by Schneider Electric 05/2009 edition ch. 1 - p. 12 Basic notions on installations with UPSs (cont.) UPS power availability What is meant by availability? Availability of an electrical installation Availability is the probability that the installation will be capable of supplying energy with the level of quality required by the supplied loads. It is expressed as a percentage. MTTR Availability (%) = (1 ) 100 MTBF The MTTR is the mean time to repair the supply system following a failure (including the time to detect the cause of the failure, repair it and start the system up again). The MTBF is the mean time between failures, i.e. the time the supply system is capable of ensuring correct operation of the loads. Example. An availability of 99.9% (called thee nines) corresponds to a 99.9% chance that the system will effectively carry out the required functions at any given time. The difference between this probability and 1 (i.e. 1 - 0.999 = 0.001) indicates the level of non-availability (i.e. one chance out of 1000 that the system will not carry out the required functions at any given time). Fig. 1.10. MTTR and MTBF. What is the practical signification of availability? Down-time costs for critical applications are very high (see fig. 1.5). These applications must obviously remain in operation as long as possible. The same is true for their electrical supply. The availability of the energy supplied by an electrical installation corresponds to a statistical measurement (in the form of a percentage) of its operating time. The MTBF and MTTR values are calculated or measured (on the basis of sufficiently long observations) for the components. They can then be used to determine the availability of the installation over the period. What are the factors contributing to availability? Availability depends on the MTBF and the MTTR. Availability would be equal to 100% if the MTTR is equal to zero (instantaneous repair) or if the MTBF is infinite (operation with no breakdowns). This is statistically impossible. Practically speaking, the lower the MTTR and the higher the MTBF, the greater the availability. From "3 nines" to "6 nines" The critical nature of many applications has created the need for much higher levels of availability for electrical power. The "traditional" economy uses power from the public utility. An average-quality distribution system with HV backup offers 99.9% availability (3 nines), which corresponds to eight hours of non-availability per year. Sensitive loads require an electrical supply capable of providing 99.99% availability (4 nines), which corresponds to 50 minutes of non-availability per year. The computer and communication equipment in data centres requires 99.9999% availability (6 nines), which corresponds to 30 seconds of non-availability per year. This level is the means to ensure, without risk of major financial loss, operation of infrastructures 24/365, without shutdown for maintenance. It is a step toward a continuous supply. APC by Schneider Electric 05/2009 edition ch. 1 - p. 13 Basic notions on installations with UPSs (cont.) The "traditional" economy uses public-utility power offering 99.9% availability, i.e. 3 nines. Sensitive loads require a 99.99% level of availability, i.e. 4 nines. Data centres require 99.9999%, i.e. 6 nines. Fig. 1.11. Evolution in the level of availability required by applications. How can availability be improved? To improve availability, it is necessary to reduce the MTTR and increase the MTBF. Reduce the MTTR Real-time fault detection, analysis by experts to ensure a precise diagnosis and rapid repair all contribute to reducing the MTTR. These efforts depend on the key factors listed below. Quality of service International presence of the manufacturer. International availability of services. The number, the qualification and the experience of service teams. The installed product base and the experience gained. Easy to maintain, modular UPSs The resources and the proximity of the technical support. Local availability of original spare parts. High-performance manufacturer methods and tools. Remote diagnostics. Training in courses adapted to customer needs. Quality and availability of documentation in the local language. APC Global ServicesTM offers a complete range of consulting services, training and audits to provide users with the knowledge required for system operation, diagnostics and level-one maintenance. TM APC Global Services Reduce the MTTR Increase availability Fig. 1.12. The quality of service is an essential factor in high availability. UPS communication capabilities User-friendly interface providing easy operating diagnostics. Communication with the electrical and computer environment. Communication and supervision of UPSs from APC by Schneider Electric, see Ch. 4. UPS communication. APC by Schneider Electric 05/2009 edition ch. 1 - p. 14 Basic notions on installations with UPSs (cont.) Increase the MTBF This goal depends primarily on the factors listed below. Selection of components with proven reliability Products with certified design, development and manufacturing processes. Performance levels certified by recognised, independent organisations. Compliance with international standards on electrical safety, EMC (electromagnetic compatibility) and performance measurement. With 40 years experience and protecting 350 GVA of critical power, solutions from APC by Schneider Electric have proven their value to the major industrial companies. All products comply with the main international standards and their level of performance is certified by recognised organisations. Certified quality and reliability Increase the MTBF Increase availability Fig. 1.13. The proven reliability of products increase the MTBF and availability. Built-in fault tolerance Fault tolerance makes possible operation in a downgraded mode following faults that may occur at different levels of the installation (see fig. 1.14). During the time required to repair, the load continues to be supplied and generates revenues. Immediate tripping: - detection and alarms - identification of causes - corrective action Fig. 1.14. Fault tolerance increases availability. Installation maintainability This is the capacity to isolate (de-energise) parts of the installation for maintenance under safe conditions, while continuing to supply the load. It should be possible: in the UPS, due to the static bypass and maintenance bypass, in other parts of the installation, depending on the architecture. Direct supply of the load during maintenance. Automatic, no-break transfer of the load to the bypass line following a downstream internal fault or overload. Fig. 1.15. Static bypass and manual maintenance bypass. APC by Schneider Electric 05/2009 edition ch. 1 - p. 15 Basic notions on installations with UPSs (cont.) APC by Schneider Electric solutions ensure fault tolerance and maintainability by implementing: double-conversion UPSs capable of transferring the load to the Bypass AC input via the automatic bypass and equipped with a maintenance bypass, redundant, multi-source UPS configurations with STS units. Key factors to the availability of installations with UPSs A few years ago, most installations were made up of single-UPS units and the number of parallel systems was small. The applications requiring this type of installation still exist. However, the shift toward high availability requires use of configurations offering redundancy at a number of levels in the installation (see fig. 1.16). Source redundancy: availability even during long utility outages. UPS redundancy: reliability, easier and safer maintenance. Redundant distribution with STS units: maximum availability. Fig. 1.16. The required levels of availability have resulted in the use of redundancy on a number of levels in the installation. This trend has led designers, depending on the criticality of the loads and the operating requirements, to take into account some or all of the key factors listed below. Reliability and availability Propose a configuration corresponding to the level of availability required by the load, comprising components with proven levels of reliability and backed up by a suitable level of service quality. Maintainability Ensure easy maintenance of the equipment under safe conditions for personnel and without interrupting operation. Upgradeability It must be possible to upgrade the installation over time, taking into account both the need to expand the installation gradually and operating requirements. Discrimination and non propagation of faults It must be possible to limit faults to as small a part of the installation as possible, while enabling servicing without stopping operations. Installation operation and management Make operations easier by providing the means to anticipate events via installation supervision and management systems. Selection of the configuration Prerequisite step in establishing installation specifications The selection of a configuration determines the level of availability that will be created for the load. It also determines the possible solutions for most of the factors listed above. The configuration may be single or multi-source, with single or parallel UPS units and with or without redundancy. Selection of the configuration is the initial step in establishing installation specifications. To assist in making the right decision, chapter 2 is entirely devoted to this subject. It compares the various configurations in terms of availability, protection of the loads, maintainability, upgradeability and cost. Configuration selection based on typical installations corresponding to different levels of availability, see Ch. 2. APC by Schneider Electric 05/2009 edition ch. 1 - p. 16 Power calculations Elements required for power calculations Installation considerations Type of load supplied Linear loads (cos ) or non-linear loads (power factor). These characteristics determine the power factor at the UPS output. Maximum power drawn by the load under steady-state conditions For a load, this is the power rating. If a number of loads are connected in parallel on the UPS output, it is necessary to calculate the total load when all the loads operate at the same time. Otherwise, it is necessary to use diversity to calculate the most unfavourable operation in terms of the power drawn. In-rush currents under transient conditions or for a short-circuit downstream The overload capacity of a UPS system depends on the time the overload lasts. If this time limit is exceeded, the UPS transfers the load to the Bypass AC input, if its voltage characteristics are within tolerances. In this case, the load is no longer protected against disturbances on the distribution system. Depending on the quality of the Bypass AC power, it is possible to: use the Bypass AC input to handle current spikes due to switching of devices or downstream short-circuits. This avoids oversizing the system, disable automatic transfer (except for internal faults), while maintaining the possibility of manual transfers (e.g. for maintenance). UPSs from APC by Schneider Electric operate in current-limiting mode. By spacing switching of devices over time, it is generally possible to handle in-rush currents without having to transfer to the Bypass AC power. If the in-rush current exceeds the limiting threshold (e.g. 2.33 In for MGE Galaxy 9000 UPSs) for a few periods (but less than one second), the UPS current limits for the necessary time. This downgraded operating mode may be acceptable, for example, for a cold start (on battery power, utility power absent). Power of a UPS Rated power of a UPS This rating, indicated in the catalogues, is in the output power. It is indicated as an apparent power Sn in kVA, with the corresponding active power Pn in kW, for a: linear load, load with a cos = 0.8. However, last-generation UPSs from APC by Schneider Electric can supply loads with a cos = 0.9 leading. Calculation of the rated power Pn (kW) = 0.8 Sn (kVA). rated active power This calculation depends on the output voltage of the UPS and the current drawn by the load, where: Sn (kVA) = UnIn 3 in three-phase systems Sn (kVA) = VnIn in single-phase systems For a three-phase UPS, U and I are rms line values, for a single-phase UPS, V is a phase-to-neutral voltage, where: Un = phase-to-phase voltage Vn = phase-to-neutral voltage Un = Vn 3 For example, if Un = 400 volts, Vn = 230 Volts. Power and type of load The two tables below present the equations linking the power, voltage and current, depending on the type of load (linear or non-linear). The following symbols are used: instantaneous voltage u(t) and current i(t) values, the corresponding rms values U and I, = angular frequency = 2 f where f is the frequency (50 or 60 Hz), = displacement between the voltage and the current under sinusoidal conditions. APC by Schneider Electric 05/2009 edition ch. 1 - p. 17 Power calculations (cont.) Linear loads Three-phase Sinusoidal voltage Single-phase u(t) = U 2 sin t v(t) = V 2 sin t between phases phase to neutral U=V 3 i(t) = I 2 sin (t - ) Displaced sinusoidal current phase current Current crest factor 2 Apparent power S (kVA) = UI 3 cos S (kVA) = VI Active power P (kW) = UI 3 cos = S (kVA) cos P (kW) = VI cos = S (kVA) cos Reactive power Q (kvar) = UI 3 sin = S (kVA) sin Q (kvar) = VI sin = S (kVA) sin S= P 2 +Q 2 Non-linear loads Sinusoidal voltage u(t) = U 2 sin t v(t) = V 2 sin t between phases The regulated UPS voltage remains sinusoidal (low THDU), whatever the type of load. phase to neutral U=V 3 i(t) = i1(t) + ihk(t) Current with harmonics total phase current i1(t) = I1 2 sin (t - 1) fundamental current ik(t) = Ihk 2 sin (kt - k) I= I12 2 2 2 + I2 + I3 + I4 + .... k-order harmonic rms value of the total current Fc = peak current value / rms value THDI = I12 2 2 Current crest factor 2 + I2 + I3 + I4 + .... I1 Current total harmonic distortion Apparent power S (kVA) = UI 3 S (kVA) = VI Active power P (kW) = UI 3 = S (kVA) P (kW) = VI = S (kVA) Power factor = P(kW ) S(kVA ) UPS percent load This is the percentage of the rated power that is effectively drawn by the load. Sload (kVA ) Load (%) = Sn (kVA ) Recommendation: take into account growth in loads It is advised to leave a margin (excess power) when setting the rated power, particularly if a site expansion is planned. In this case, make sure the percent load on the UPS is still acceptable after the expansion. UPS efficiency This factor determines the power drawn by the UPS on the upstream distribution system, i.e. the consumption. It may be calculated as: PUPSoutput (kW ) (%) = PUPSinput (kW ) For a given power rating, a high level of efficiency: reduces power bills, reduces heat losses and, consequently, ventilation requirements. APC by Schneider Electric 05/2009 edition ch. 1 - p. 18 Power calculations (cont.) It is possible to calculate the efficiency at full rated load, i.e. with a 100% load. Pn (kW ) n (%) = PUPSinput (kW ) The rated active power of the UPS is obtained by multiplying the rated apparent power Sn (kVA) by 0.8 (if > 0.8) or by (if < 0.8). The efficiency can vary significantly depending on the percent load and the type of load. The installation designer must therefore pay attention to two aspects of efficiency. Recommendation 1: check the efficiency for non-linear loads The presence of non-linear loads tends to reduce the power factor to values below 0.8. It is therefore necessary to check the efficiency value for standardised non-linear loads. This check is recommended by standards IEC 62040-3 / EN 62040-3. Recommendation 2: check the efficiency at the planned percent load Manufacturers generally indicate the efficiency at full rated load. However, its value may drop if the percent load is lower (1). Attention must therefore be paid to UPSs operating in an active-redundancy configuration, where the units share the total load and often operate at 50% of their full rated load, or less. (1) A UPS is optimised to operate at full rated load. Even though losses are at their maximum at full rated load, the efficiency is also at its maximum. In a standard UPS, losses are not proportional to the percent load and the efficiency drops sharply when the percent load drops. This is because a part of the losses is constant and the relative percentage of this part increases when the load decreases. To obtain high efficiency at low load levels, the constant losses must be very low. Due to their design, UPSs from APC by Schneider Electric have very low constant losses and as a result, the efficiency is virtually stable for loads from 30 to 100%. UPS efficiency, see Ch. 5 p. 20. Ratings of single-UPS configurations Single-UPS configurations These configurations comprise a single, double-conversion UPS unit (see fig. 1.17). The overload capacity at the UPS output is indicated by a diagram (the example below is for the MGE Galaxy 9000 range). In the event of an internal fault or an overload exceeding UPS capacity, the system automatically transfers to the Bypass AC input. If transfer is not possible, UPSs from APC by Schneider Electric current limit for overloads greater than the maximum value (e.g. 2.33 In peak for one second for Galaxy 9000, which corresponds to a maximum sine wave with an rms value of 2.33 / 2 = 1.65 In). Beyond one second, the UPS shuts down. A set of disconnection switches is available to isolate the UPS for maintenance in complete safety. Fig. 1.17. Single double-conversion static UPS unit and example of an overload curve. APC by Schneider Electric 05/2009 edition ch. 1 - p. 19 Power calculations (cont.) Power levels under steady-state conditions A UPS is sized using the apparent rated output power Sn (kVA) and an output power factor of 0.8. These conditions correspond to an active rated power of Pn (kW) = 0.8 Sn (kVA). In real-life situations, a UPS supplies a number of loads with an overall power factor that is often not 0.8 due to the presence of non-linear loads and means to improve the power factor; If 0.8, the UPS is still limited to Pn (kW), If < 0.8, the UPS is limited to Sn (kW) < Pn (kW). Consequently, selection of the power rating in kVA must take into account the active power supplied to the loads. The active power is determined by following the four steps below. 1 - Apparent and active power drawn by the loads The first step is to evaluate the power requirements of the load. The table below must be drawn up for the k loads to be supplied. Load Load 1 Load 2 … Load i … Load k Total Apparent rated power (kVA) S1 S2 Input power factor (or cos ) 1 2 Active rated power (kW) P1 = 1 S1 P2 = 2 S2 Si i Pi = i S i Sk S (1) S is not the sum of Si. k (2) must be measured or calculated. Pk = k S k P = S (3) P = S = i S i (1) S is not the sum of Si because: - it would be necessary to calculate the vectoral sum if all the loads were linear, using the angles of the different cos , - some of the loads are not linear. (2) must be measured on site or evaluated on the basis of past experience. (3) P = S = i S i because the active power is added (no displacement). 2 - Rated apparent power of the UPS (Sn) The second step is to select a UPS with an apparent-power rating sufficient to cover the load requirements (in kVA). Under the given conditions, the suitable rated apparent power for the UPS is: Sn(kVA) > S. where S = P / . In the UPS range, select the UPS with a rated power Sn (kVA) just above S. If reserve power is required and the selected rating is too close to S, select the next highest rating. 3 - Check on the active power The third step is a check to ensure that the selected power rating can cover the load requirements in kW under the stipulated operating conditions. For the selected rating, the UPS will supply the rated active power Pn (kW) = 0.8 Sn (kVA) If 0.8, make sure that Pn (kW) > P, i.e. that the UPS can supply the additional power required, otherwise select the next highest rating. If < 0.8, the power supplied by the UPS is sufficient because Pn (kW) > Sn (kVA), i.e. the selection is correct. 4. - Percent load The fourth step is a check to ensure that the percent load is acceptable now and in the future, given the desired operating conditions. The percent load is: Load = S / Sn(kVA) . It must be sufficient to cover any increases in the load or if there are plans to expand the system to become redundant. APC by Schneider Electric 05/2009 edition ch. 1 - p. 20 Power calculations (cont.) Power levels under transient conditions Load in-rush currents It is necessary to know the in-rush current of each load and the duration of the transient conditions. If a number of loads risk being turned on at the same time, it is necessary to sum the in-rush currents. Necessary checks It is then necessary to check that the planned UPS power rating can handle the inrush currents. Note that the UPS can operate for a few periods in current-limiting mode (e.g. 2.33 In for one second for an MGE Galaxy 9000). If the UPS cannot handle the in-rush currents, it is necessary to decide whether it is acceptable to transfer to the Bypass AC input when the transient conditions occur. If transfer is not acceptable, it is necessary to increase the power rating. Review of in-rush currents, see Ch. 5 p. 37. Example The example below is simply to illustrate the point and does not correspond to a real situation. The purpose is to indicate the required steps. The installation is made up of three 400 V three-phase loads connected in parallel: Computer system - S1 = 4 x 10 kVA (4 identical 10 kVA loads), = 0.6 for all the loads, in-rush current 8 In over four periods 50 Hz (80 ms) for each load, Variable-speed drive - S2 = 20 kVA, = 0.7, in-rush current 4 In over five periods (100 ms), Isolation transformer - S3 = 20 kVA, = cos = 0.8, in-rush current 10 In over six periods (120 ms). Rated apparent output power Sn(kVA) Active power Pn(kW) = 0.8 Sn(kVA) Power factor at UPS output for all loads Total power consumed by the loads 4 x 10 kVA P (kW) = 54 kW 1 = 0.6 Fig. 1.18. Example of an installation. 20 kVA 2 = 0.7 20 kVA cos = 0.8 Maximum active output power (that the UPS can supply to the loads) Sn (kVA) Power levels under steady-state conditions 1 - Apparent and active power drawn by the loads Below is the table that should be drawn up. Load Computer system Variable-speed drive LV/LV transformer Total Rated apparent power (kVA) 40 20 20 S Input power factor 0.8* 0.7 0.8 = 0.68 measured or estimated Rated active power (kW) 32* 14 16 P = 54 kW * average of new top of the range systems with power factor 0.9 and older equipment with power factor between 0.7 and 0.8. 2 - Rated apparent power of the UPS S = 54 / 0.68 = 79.4 kVA A Galaxy PW UPS with a sufficient rating should be selected. The 80 kVA rating would not be sufficient, i.e. the 100 kVA rating should be selected or higher if a site extension is planned. APC by Schneider Electric 05/2009 edition ch. 1 - p. 21 Power calculations (cont.) 3 - Check on the active power The UPS can supply the loads 100 x 0.68 = 68 kW > 54 kW. 4 - Checks on the percent load and rated current The percent load is therefore 79.4 / 100 = 79.4%. Rated current of the UPS - Sn (kVA) = UI 3 , i.e. I = 100 / (400 x 1.732) = 144 A. In-rush currents under transient conditions The loads should be started up one after the other to avoid combining the in-rush currents. It is necessary to check that the UPS can handle the in-rush currents. The rated currents are calculated as S (kVA) = UI 3 , i.e.: Computer system - In = 10 / (400 x 1.732) = 14.4 A, i.e. 8 In 115 A for 80 ms Variable-speed drive - In = 20/(400 x 1.732) = 28.8 A, i.e. 4 In 115 A for 100 ms Transformer - In = 20 / (400 x 1.732) = 28.8 A, i.e. 10 In = 288 A for 120 ms A 100 kVA MGE Galaxy PW UPS has an overload capacity of 120%, i.e. 151 A x 1.2 = 173 A for 1 minute and 150%, i.e. 151 A x 1.5 = 216 A for 1 minute Operation in current-limiting mode at 2.33 In, i.e. 335 A for one second. If the four computer loads (10 kVA each) are started one after the other, the 20% overload capacity of the UPS is sufficient (173 A -1mn > 115 A - 80 ms). If the four loads are started simultaneously, the in-rush current would be 4 x 115 = 460 A > 335 A. The system would current limit for 80 ms. For the variable-speed drive, the overload capacity is sufficient. For the isolation transformer (288 A for 120 ms), the overload capacity is again sufficient. Ratings of parallel-UPS configurations Parallel-UPS configurations Purpose of parallel connection Parallel connection of a number of identical units is the means to: increase the power rating, establish redundancy that increases the MTBF and availability. Types of parallel connection Two types of UPS units can be connected in parallel. Integrated parallel UPS units - each UPS unit includes an automatic bypass and a manual maintenance bypass. The manual bypass may be common to the entire system (in an external cubicle). Parallel UPS units with an SSC - the static-switch cubicle comprises an automatic bypass and a maintenance bypass that are common for a number of parallel units without bypasses (see fig. 1.19). True modular parallel systems are also available, made up of dedicated and redundant modules-power, intelligence, battery and bypass, all engineered into a design that is easily and efficiently serviceable. Power modules can be easily added as demand grows or as higher levels of availability are required. There are two types of parallel configurations: Without redundancy - all the UPS units are required to supply the load. Failure of one unit means the entire system shuts down (not recommended), With redundancy N+1, N+2, etc. - the number of UPS units required for the load is equal to N. All the UPS units (N+1, N+2, etc.) share the load. If one UPS unit shuts down, the remaining units (at least equal in number to N) continue to share the load. Typical configurations and characteristics, see Ch. 2. Fig. 1.19. UPS system with parallel-connected units and a static-switch cubicle (SSC). APC by Schneider Electric 05/2009 edition ch. 1 - p. 22 Power calculations (cont.) Power levels in redundant parallel configurations In a redundant parallel configuration made up of identical units, the units share the load. The power rating of each unit does not depend on the level of redundancy, but must be calculated to continue supplying the load even if redundancy is completely lost. Active redundancy: improves availability, increases the overload capacity, reduces the percent load on each UPS unit. The power level is determined by following the same four steps as for a single-UPS configuration. 1 - Apparent and active power drawn by the loads The same type of table is used as that for a single UPS (see Ch1 p. 20). The result is the apparent power S that must be supplied to the load. 2 - Rated apparent power of the UPS units (Sn) in the configuration Consider a level of redundancy N + K (e.g. 2 + 1), which means: - N units (e.g. 2) are required to supply the load, - K units (e.g. 1 extra unit) ensure redundancy. Each UPS unit must be sized to enable the system as a whole to operate without redundancy, i.e. with N operational units and K units shut down. In this case, the N units must each have an apparent power rating Sn (kVA) such that: Sn(kVA) > S / N. Select in the UPS range the power rating Sn (kVA) just above S/N. If reserve power is required or the selected rating is too close to S, select the next highest rating. 3 - Check on the active power For the selected rating, the UPS will supply the active rated power Pn (kW) = 0.8 Sn (kVA) if 0.8, make sure that Pn (kW) > P, i.e. that the UPS can supply the additional power required, otherwise select the next highest rating. if < 0.8, the power supplied by the UPS is sufficient because Pn (kW) > Sn (kVA), i.e. the selection is correct. 4 - Percent load With redundancy, the UPS units share the load according to the equation S / (N+K). The percent load for each unit when there is redundancy is therefore: TL = S / (N + k) Sn(kVA) . In a non-redundant system, it is calculated as: TL = S / N Sn(kVA). It must be sufficient to cover any increases in the load. Example This example will use the results from the last example and we will suppose that the loads are critical, i.e. redundancy is required. The total load is 54 kW with an overall power factor for all the loads of 0.68, i.e. S = 54 / 0.68 = 79.4 kVA. If 2+1 redundancy is used, two units must be capable of supplying the load. Each must will have to supply S / 2 = 79.4 / 2 = 39.7 kVA. An MGE Galaxy PW UPS with a sufficient rating should be selected. The 40 kVA rating would not be sufficient, i.e. the 50 kVA rating should be selected or higher if a site extension is planned. If redundancy is not available, the two UPS units must be capable of supplying the load. This is the case because 2 x 50 x 0.68 = 68 kW > 54 kW. During operation, the percent load will be: - with redundancy, i.e. with 3 UPS units sharing the load: 79.4 / 3 x 50 = 52.9%, - without redundancy, i.e. with only 2 UPS units sharing the load: 79.4 / 2 x 50 = 79.4%. APC by Schneider Electric 05/2009 edition ch. 1 - p. 23 Control of upstream harmonics UPSs and upstream harmonics Role of the input rectifier UPS units draw power from the AC distribution system via a rectifier/charger. With respect to the upstream system, the rectifier is a non-linear load that causes harmonics. In terms of harmonics, there are two types of rectifiers. Standard rectifiers These are three-phase rectifiers incorporating SCRs and using a six-phase bridge (Graetz bridge) with standard chopping of the current. This type of bridge draws harmonic currents with orders of n = 6 k 1 (where k is a whole number), mainly H5 and H7, and to a lesser degree H11 and H13. Harmonics are controlled by using a filter (see fig. 1.20). PFC-type transitor-based controlled active rectifiers These transistor-based active rectifiers have a regulation system that adjusts the input voltage and current to a reference sine wave. This technique ensures an input voltage and current that are: perfectly sinusoidal, i.e. free of harmonics, in phase, i.e. with a power factor close to 1. With this type of rectifier, no filters are required. Clean transitor-based rectifiers, see Ch. 4. All high-power UPS ranges from APC by Schneider Electric (except MGE Galaxy PW and and MGE Galaxy 9000) use PFC type controlled active rectifier technologies and therefore do not generate harmonics. Fig. 1.20. Input rectifier and harmonics. APC by Schneider Electric 05/2009 edition ch. 1 - p. 24 Control of upstream harmonics (cont.) Filtering of upstream harmonics for UPSs with Graetz bridge rectifiers Goals of harmonic filtering This section concerns only the MGE Galaxy PW and MGE Galaxy 9000 ranges and UPSs with conventional Graetz bridge rectifiers. A "clean" upstream system The goal is to ensure a level of voltage distortion (THDU) on the busbars supplying the UPS that is compatible with the other connected loads. The UTE recommends limiting the THDU to: 5% when the source is a generator, 3% when the source is a transformer to take into account 1 to 2% of THDU which may already be present on the HV distribution system. This recommendation may differ for each country. Practically speaking, solutions for voltage distortion (THDU) must be implemented in a manner specific to the country where the installation is located. Easy combination with an engine generator set The goal is to make possible a UPS/engine generator set combination with no risk of increasing the level of harmonics when the load is transferred to the generator. This risk exists because the generator has a source impedance lower than that of a transformer, which increases the effects of harmonics. High power factor at the rectifier input The goal is to increase the input power factor (generally to a level higher than 0.94). This reduces the consumption of kVA and avoids oversizing the sources. Installation complying with standards The goal is to comply with standards concerning harmonic disturbances and with the recommendations issued by power utilities. Standards on harmonic disturbances (see table 1.2) - IEC 61000-3-2 / EN 61000-3-2 for devices with an input current 16 A/ph. - IEC 61000-3-4 / EN 61000-3-4 for devices with an input current > 16 A/ph. Standards and recommendations on the quality of distribution systems, notably: - IEC 61000-3-5 / EN 61000-3-5, - EN 50160 (Europe), - IEEE 519-2 (United States), - ASE 3600 (Switzerland), - G5/3 (U.K.), etc. Standards on harmonics, see "UPS standards" in Ch. 5, p. 29. Table 1.2. Example of harmonic-current limitations as per guide IEC 61000-3-4 / EN 61000-34 for devices with an input current > 16 A/ph (stage 1, simplified connection). Harmonic % of H1 (fundamental) H3 21.6% H5 10.7% H7 7.2% H9 3.8% H11 3.1% H13 2.0% H15 0.7% H17 1.2% H19 1.1% H21 0.6% H23 0.9% H25 0.8% H27 0.6% H29 0.7% H31 0.7% H33 0.6% Even orders 0.6% or 8/n (n even order) Types of harmonics filters Harmonics filters eliminate certain orders or all orders, depending on their technology. The following types are available. APC by Schneider Electric 05/2009 edition ch. 1 - p. 25 Control of upstream harmonics (cont.) Passive LC filters non-compensated compensated non-compensated with contactor Double-bridge rectifier Phase-shift filter THM active filter (Active 12-pulse technology). Filtering and parallel connection When a number of UPS units are connected in parallel and depending on the type of filter used, it is possible to install: an individual filter on each UPS unit, a common filter for the entire parallel configuration. The goal is to achieve a balance between cost and effectiveness, taking into account the acceptable levels of harmonic distortion. The comparison tables for the various solutions (Ch. 1, p. 28) are helpful in making a selection. Combination of LC filters and generator The generator can supply only relatively low capacitive currents (10 to 30% of In). When an LC filter is installed, the main difficulty lies in the gradual start-up of the rectifier on generator power, when active power is equal to zero and the generator supplies only the capacitive current for the filter. Consequently, the use of LC filters must be correctly analysed to ensure that operation complies with manufacturer specifications. Below is a method for selection of LC filters, using as an example a generator derating curve, similar to those provided by manufacturers. Fig. 1.21. Derating curve for a generator, as a function of the installation power factor. The curve in the figure above, provided as one example among many, shows the power derating as a function of the operating point, for a given generator. For a purely capacitive load (= 0), the power available is equal to only 30% of the rated power (point A). If we assume an apparent power rating such that Pn generator = Pn rectifier, the meaning of points A, B, C, D, E and F is the following: A: reactive power corresponding to the capacitive current of a non-compensated filter, B: reactive power corresponding to the capacitive current of a compensated filter, C: operating point at start-up with a non-compensated filter with contactor, D: operating point at the rated load with a non-compensated filter, E: operating point at the rated load with a compensated filter, F: operating point at the rated load, without a filter or with a phase-shift filter. APC by Schneider Electric 05/2009 edition ch. 1 - p. 26 Control of upstream harmonics (cont.) Example Consider a non-compensated filter with a 300 kVA generator and a 200 kVA MGE Galaxy PW UPS. The power rating of the rectifier, taking 87% as the efficiency value (1 / 0.87 = 1.15), is 1.15 times that of the inverter, i.e. 200 x 1.15 = 230 kVA. The capacitive current of the non-compensated filter is 230 x 30% (1) = 69 kVA. The reactive power that the generator can handle (point A) is 300 x 0.3 = 90 kVA. The filter is therefore compatible with the generator. (1) The value of 30% has been determined experimentally. Selection of a filter Selection parameters for a filter Overall effectiveness - reduction in distortion (THDI and THDU) The effectiveness depends on the harmonic orders filtered and the degree to which they are attenuated or eliminated. It is measured by the THDI at the rectifier input. The impact on the THDI determines the level of the THDU. It is necessary to check the performance at the planned percent load, given that many UPS systems operate at percent loads between 50 and 75%. Improvement in the power factor The filter improves the power factor (generally to a level higher than 0.92). Compatibility with an engine generator set It is also necessary to check the performance with the planned source(s), either a transformer or an engine generator set. This is because the generator has an output impedance lower than that of a transformer, which increases the effects of harmonics. Suitable for parallel-UPS configurations Depending on the type of filter, it is possible to install one on each UPS unit or set up a single filter for overall elimination of harmonics. Efficiency Consumption of the filters can slightly modify the efficiency of the installation as a whole. Flexibility for set-up and upgrades Filters are generally specific to a UPS and may be factory-mounted or installed after installation. The SineWave conditioner provides overall elimination of harmonics and great flexibility in the configuration. Dimensions It is necessary to check whether the filter can be installed in the UPS cabinet or in a second cabinet. Cost It impacts on the effectiveness of the filter and must be weighed against the advantages obtained. Compliance with standards It is necessary to determine compliance with standards, in particular IEC 61000-3-4, in terms of the individual harmonic levels indicated in the texts. Comparison table of solutions The following tables list the elements for comparison, with a general comment on use of each type of solution. Table 1.3 presents individual solutions for single-UPS configurations. These solutions may also be used in parallel configurations. Table 1.4 presents overall solutions for entire configurations. APC by Schneider Electric 05/2009 edition ch. 1 - p. 27 Control of upstream harmonics (cont.) Table 1.3. Comparison of individual harmonic-filtering solutions. Type of filter Criterion Diagram Reduction in distortion THDI at 100% load THDI at 50% load Harmonics eliminated LC noncompensated LC compensated LC with contactor Double bridge Built-in THM Fig. 1.22a Fig. 1.22b Fig. 1.22c Fig. 1.22d Fig. 1.22e 7 to 8% 10% H5, H7 7 to 8% 10% H5, H7 7 to 8% 10% H5, H7 10% 15% H5, H7, H17, H19 4% 5% H2 to H25 0.95 1 0.95 1 0.95 1 0.85 0.8 0.94 0.94 * ** ** ** *** *** * *** *** *** * *** *** *** * *** *** * * * * ** *** ** *** * * * * ** Fig. 1.22f Fig. 1.22g Fig. 1.22h Fig. 1.22i Fig. 1.22j no no no no yes Power factor at 100% load at 50% load Compatibility with generator Efficiency of filter Flexibility, upgradeability Cost Dimensions Connection in parallel with UPS Compliance with guide IEC 61000-3-4 General comment *** Excellent ** Good APC by Schneider Electric Solution suitable for installations without an engine generator set. Solution suitable for installations with an engine generator set. The added inductor load reduces the capacitive power that must be supplied by the engine-generator set. Solution suitable for Solution suitable for installations installations with comprising an engine gensets generator set with a power rating lower than that of the UPS. The LC line is switched in by the contactor at a preset value corresponding to an inverter percent load that is acceptable for the engine generator set. Solution suited to sensitive installations or with changing load levels. The most effective and the most flexible solution. Does not depend on the percent load or the type of upstream source. * Sufficient 05/2009 edition ch. 1 - p. 28 Control of upstream harmonics (cont.) Table 1.4 Comparison of overall solutions. Type of filter SineWave Criterion Diagram Phase-shift filter AC input SW UPS UPS UPS Load Fig. 1.23b Fig. 1.23a Reduction in distortion THDI at 100% load THDI at 50% load 4% 5% Harmonics eliminated H2 to H25 Fig. 1.23c Fig. 1.23d < 10% < 5% < 4% 35% with 1 UPS shut 19% with 1 UPS shut 12% with 1 UPS shut down down down Power factor at 100% load at 50% load Compatibility with generator Efficiency of filter Flexibility, upgradeability Cost Dimensions Compliance with guide IEC 61000-3-4 General comment *** Excellent ** Good APC by Schneider Electric 0.95 1 0.8 0.8 *** ** *** *** *** *** ** * *** * yes yes Solution suited to sensitive installations or with changing load levels. The most effective and the most flexible solution. Does not depend on the percent load or the type of upstream source. Solution cannot be modified. Suited to installations with more than two parallel-connected UPS units. * Sufficient 05/2009 edition ch. 1 - p. 29 System earthing arrangements Background information on system earthing arrangements Protection of persons against electrical contact International standards require that electrical installations implement two types of protection of persons against the dangers of electrical currents. Protection against direct contacts The purpose of this form of protection is to avoid "direct" contact between persons and intentionally live parts (see fig. 1.24). It includes the points listed below. isolation of live parts using barriers or enclosures offering a degree of protection at least equal to IP2X or IPXXB. opening of the enclosure (doors, racks, etc.) must be possible only using a key or a tool, or following de-energising of the live parts or automatic installation of a screen. connection of the metal enclosure to a protective conductor. Protection against indirect contacts and system earthing arrangements The purpose of this form of protection is to avoid "indirect" contact between persons and exposed conductive parts (ECP) that have become live accidentally due to an insulation fault. The fault current creates in the exposed conductive parts (ECP) a potential that may be sufficient to cause a dangerous current to flow through the body of the person in contact with the exposed conductive parts (see fig. 1.24). This protection includes the points listed below. mandatory earthing of all exposed conductive parts (ECP) that may be accessed by the user. The protective conductor is used for connection to the earth. It must never be interrupted (no breaking devices on the protective conductor). The interconnection and earthing techniques for the exposed conductive parts (ECP) determine the system earthing arrangement (SEA) for the installation. disconnection of the supply when the potential of the ECPs risks reaching dangerous levels. Interruption is carried out by a protection device that depends on the selected system earthing arrangement (SEA). It often requires residual-current devices (RCD) because the insulation-fault currents are generally too low to be detected by standard overcurrent protection devices. Fig. 1.24. Direct and indirect contacts. Types of system earthing arrangements (SEA) There are three types of system earthing arrangements (SEA). Isolated neutral (IT). Earthed neutral (TT). Exposed conductive parts connected to the neutral (TN with TN-C and TN-S). The first two letters indicate how the neutral and the ECPs of the loads are connected. T = earthed neutral T = exposed conductive parts Third letter (for TN) Type of protective conductor C = Common neutral and earthed protective conductor (PEN) I = isolated neutral N = exposed conductive parts S = Separate neutral (N) and Second letter First letter Connection of the neutral Connection of the ECPs connected to the neutral IT, TT or TN systems APC by Schneider Electric 05/2009 edition protective conductor (PE) TN-C or TN-S ch. 1 - p. 30 System earthing arrangements (cont.) System earthing arrangements (SEA) Isolated neutral (IT) ● The source neutral is: - either isolated from the earth (isolated neutral), - or connected to the earth via a high impedance res (impedant neutral). ● The exposed conductive parts (ECP), all protected by the same breaking device, are earthed (earth electrode resistance RA). L1 L2 L3 N PE Zres Id Ud RA E.g. Phase-to-ECP fault in a load. Uo is the phase-to-neutral voltage in the distribution system (230 V). ● Current of the first fault RA= 10 and Zres= 3500 (approximately), Id = Uo / (RA + Zres) = 66 mA. ● Voltage of the first fault Ud = Uo x RA / (RA + Zres) = 0.66 V. This potential is not dangerous. The fault must be detected by an IMD (insulation monitoring device), located by a fault-locating device and repaired. ● Current of the second fault A second fault occuring before the first fault has been repaired results in the flow of a phase-to-phase or phase-to-neutral short circuit. It must be cleared by the overcurrent protection devices within the time limits set by the standards. Fig. 1.25. IT system. Earthed neutral (TT) ● The source neutral is earthed. ● The exposed conductive parts (ECP), all protected by the same breaking device, are earthed (earth electrode resistance RA). L1 L2 L3 N PE RB Id Ud RA E.g. Phase-to-ECP fault in a load. Uo is the phase-to-neutral voltage in the distribution system (230 V). ● Fault current E.g. RA = 10 and RB = 5 Id = Uo / (RA + RB) = 15.3 A ● Fault voltage Ud = Uo x RA / (RA + RB) = 153 V This potential is dangerous (> 50 V). The fault must be cleared by the protection devices within the times set by the standards. The fault current is low and must therefore be detected by a residual-current protection device (RCD) that actuates the protective device immediately upstream. The operating current of the RCD and the time required to clear the fault are set by the standards. Fig. 1.26. TT system. Exposed conductive parts connected to the neutral (TN) ● Impedance of the fault loop ● The source neutral is directly earthed. ● The installation ECPs are connected to the Zb = ZABCDEF (part of circuit ABCDEF) neutral and consequently to the earth via the protective conductor (PEN). This arrangement transforms all insulation faults into phase-toneutral short-circuits. ● The potential of the protective conductor is maintained close to that of the earth by numerous connection points. A Id F E L1 L2 L3 B PEN D C Ud Zb ZBCDE 2 ZDE because ZBC = ZDE (BC and DE are identical, the fault impedance is negligible) E.g. A load supplied by a 50 mm² copper cable that is 50 metres long (phase and PE). 2 Zb = 2 L / S where = 22.5 . mm /m -3 Zb = 2 x 22.5 10 x 50 / 50 = 45 m. ● Fault voltage A voltage drop of 20% is permissible for the phase-to-neutral voltage Uo, i.e. UBE = 0.8 Uo. In that ZBC = ZDE, the potential of the ECPs rises to Ud = UBE / 2 = 0.8.Uo / 2 = 92 V ● Fault current -3 Id = 0.8 Uo / Zb = 0.8 x 230 / 45 10 = 4089 A Breaking is carried out by the overcurrent protection devices within the times set by the standards. The fault current depends on the impedance of the fault loop. Care must be taken to ensure that at all points in the system, the fault current is greater than the operating threshold of the protection devices. Fig. 1.27. TN-S system (the basic principle is identical for the TN-C system). APC by Schneider Electric 05/2009 edition ch. 1 - p. 31 System earthing arrangements (cont.) Comparison of system earthing arrangements (SEA) Type of SEA Operation Protection of persons Specific equipment Advantages and disadvantages EMC IT (isolated neutral) TT (earthed neutral) ● Signalling of first insulation ● Disconnection for the first TN-S (ECP to neutral) ● Disconnection for the first TN-C (ECP to neutral) ● Disconnection for the first fault. ● Location and elimination of the first fault. ● Disconnection for the second fault. ● Interconnection and earthing of ECPs. ● First fault: - very low current, - monitoring/indication by an IMD. ● Second fault: - potentially dangerous current, - interruption by overcurrent protection devices (e.g. circuit breaker). Insulation-monitoring device (IMD) and fault-locating device. ● Solution offering the best continuity of service (the first fault is signalled). ● Requires competent surveillance personnel (location of the first fault). ● High EMC performance, very low currents in the earth cable. insulation fault. insulation fault occurs ● Separate neutral (N) and protective conductor (PE). insulation fault. ● Common neutral and protective conductor (PEN). ● Earthing of ECPs ● Interconnection and ● Interconnection and combined with use of residual-current devices (RCD). ● First fault: - leakage current is dangerous, but too low to be detected by the overcurrent protection devices, - detection by the RCDs combined with breaking devices. Residual-current devices (RCD). earthing of ECPs and neutral imperative. ● first fault: - fault current, - interruption by overcurrent protection devices (e.g. circuit breaker). earthing of ECPs and neutral imperative. ● First fault: - fault current, - interruption by overcurrent protection devices (e.g. circuit breaker). ● Easiest solution to design ● High installation costs for ● Reduced installation costs and install. ● Mandatory use of RCDs. ● Different earth electrodes (distant sources). ● Highly sensitive to lightning strikes. high power ratings. ● Difficult to design (calculation of the loop impedances). ● Flow of high fault currents. ● High EMC performance, low current in the PE during normal operation. (one less conductor). ● Difficult to design (calculation of the loop impedances). ● Flow of high fault currents. ● Low EMC performance, high currents in the PEN (connections between ECPs). ● Large commercial premises, tall buildings, etc. ● Industries without continuous processes (IT system). ● Supply of computer systems. ● Commercial and continuity of service, e.g. residential premises, public hospitals, airports, industrial lighting, schools, etc. processes, ships. ● Installations and premises where there is a risk of fire or explosion, i.e. mines, etc. ECP = Exposed conductive parts. Use ● Installations requiring Applications in UPS installations For long distances, RCDs must be used. ● Large commercial premises, tall buildings, etc. ● Industries without continuous processes (IT system). ● Supply of computer systems. Specific aspects in systems with UPSs Implementation of the above protection systems in installations comprising a UPS requires a number of precautions for a number of reasons: The UPS plays two roles: - a load for the upstream system, - a power source for the downstream system, When the battery is not installed in a cabinet, an insulation fault on the DC system can lead to the flow of a residual DC component. This component can disturb operation of certain protection devices, notably RCDs used for the protection of persons. Protection against direct contact All APC by Schneider Electric UPS installations satisfy the applicable requirements because the equipment is installed in cabinets providing a degree of protection IP 20. This is true even for the battery when it is housed in a cabinet. When the battery is not installed in a cabinet (generally in a special room), the measures presented at the end of this chapter should be implemented. APC by Schneider Electric 05/2009 edition ch. 1 - p. 32 System earthing arrangements (cont.) Protection against indirect contact Selection of a system earthing arrangement A basic protection measure required by the standards is the creation of a standardised system earthing arrangement both upstream and downstream of the UPS. The two systems can be the same or different if certain precautions are taken. In an existing installation to which the UPS is added, the upstream system is already determined. Selection of the downstream system, either the same or a different one, depends on its compatibility with sensitive loads. The table on the previous page provides the necessary elements to compare the various standardised system earthing arrangements. Caution, local regulations may prohibit certain types of system earthing arrangements. Selection of the breaking devices Above and beyond the interconnection and earthing of the exposed conductive parts in compliance with a standardised system earthing arrangement, the protection of persons must be ensured by breaking devices selected according to the system earthing arrangement. These devices must cause tripping of the overcurrent protection devices in the event of an insulation fault. Tripping may: be directly provoked by suitable settings on the overprotection devices (circuit breakers, fuses), or require (mandatory for the IT system) use of residual-current devices (RCD) that may or may not be built into the circuit breaker. The RCDs are required to detect the insulation-fault currents that are often too low to trip standard overcurrent protection devices. Check local requirements concerning the safety of electrical installations. Types of systems for UPSs The possible systems depend on: the existing or selected system upstream of the UPS, the system downstream of the UPS for which selection may be determined by: - reuse of the same system as upstream, - the presence of isolation transformers upstream or downstream which make it possible to change the system earthing arrangement, - the loads (e.g. computer systems require a TN-C or TN-s system), - the organisation of the downstream distribution system, with static transfer switches (STS), certain requirements imposed by standards, e.g. the protective conductor PE or PEN must never be interrupted to ensure flow of the fault current. A TN-C system (non-interrupted PEN) can be installed upstream of a TN-S system (separate N and PE conductors), but not the contrary. See WP 98 UPSs are increasingly designed without transformers, offering advantages in terms of weight, size and efficiency. Transformerless technology also makes it possible to modulate the voltage for improved adapatation to all types of loads, in particular nonlinear loads with harmonics. Transformerless technology has an impact on the use of system earthing arrangements. For more information see White Paper - WP 98: "The Elimination of Isolation Transformers in Data Center Power Systems"). Many different cases may be encountered depending on the upstream and downstream earthing arrangements and the type of UPS. Your APC by Schneider Electric representative has a complete set of diagrams for all system earthing arrangements and UPS ranges concerned. The MGE Galaxy PW and MGE Galaxy 9000 ranges are designed with isolation transformers. All the other ranges use transformless technology with the neutral recreated electronically. The following pages show some examples for MGE Galaxy PW and MGE Galaxy 5000, 7000 and 9000 UPSs. For other cases, contact your APC by Schneider Electric representative to obtain the applicable diagram. APC by Schneider Electric 05/2009 edition ch. 1 - p. 33 System earthing arrangements (cont.) Output transformer (MGE Galaxy PW and 9000) No output transformer (MGE Galaxy 5000 and 7000)) Separate Normal and Bypass AC inputs. Common Normal and BP inputs. Fig. 1.28. Standard diagrams. Identical systems upstream and downstream Same system upstream and downstream IT or TT or TN-S. Distributed neutral on the two lines. Same system upstream and downstream IT or TT or TN-S. Distributed neutral on the bypass line only. Same system upstream and downstream TN-C Same system upstream and downstream IT or TT or TN-S. Distributed neutral. MGE Galaxy PW and 9000 MGE Galaxy 5000 and 7000 Fig. 1.29. A few examples with the same system upstream and downstream. Different systems upstream and downstream Change in earthing systems to IT or TT or TN-S downstream. Distributed neutral on the two lines. Change in earthing systems to IT or TT or TN-S downstream. Distributed neutral on the two lines. Change in earthing systems to TN-C downstream. Change in earthing systems to TN-C downstream. MGE Galaxy PW and 9000 MGE Galaxy 5000 and 7000 Fig. 1.30. A few examples with different systems upstream and downstream. APC by Schneider Electric 05/2009 edition ch. 1 - p. 34 Protection Protection using circuit breakers The protection system for installations with UPS units presented here will implement circuit breakers. Below is a presentation of the main characteristics of circuit breakers and their trip units. The part number mentioned as examples pertain to Schneider Electric circuit breakers. Other characteristics, such as limiting thermal stress and current, are among the strong points of the Compact NSX range of circuit breakers, but will not be discussed here. For further information, see the Schneider Electric low-voltage and mediumvoltage distribution catalogue and the "Electrical installation guide". Trip units Technology There are two types of trip units: thermal-magnetic, electronic. Construction built-in (thermal-magnetic only). interchangeable. Comparison Thermal-magnetic trip units are simple and inexpensive. Electronic trip units offer more precise and comprehensive settings for better adaptation to installations and their requirements. The table below sums up the characteristics of both types of trip units for circuitbreakers from 1 to 630 A and should enable you to solve most of the problems commonly encountered (from 1 to 400 kVA). Figure 1.31 presents the characteristic curves for the trip units. Protection Symb. Definition Availability Overload protection (thermal or long delay) (1) Long delay (2) Ir Overload current setting. All trip units. tr Short-circuit protection (magnetic or short delay) (3) Short delay (4) Im or Isd Applies a long tripping delay (e.g. Electronic trip units (e.g. for motor starting). Micrologic 2, 5, 6). Short-circuit current setting. On All trip units. electronic trip units, Isd is a function of Ir (generally 2 to 10 Ir). Short-circuit protection, instantaneous trip (5) tm or tsd Ii Applies a short tripping delay (e.g. for time discrimination with downstream circuit breaker). Instantaneous short-circuit setting. Depends exclusively on trip-unit rating (e.g. protection of static switches). Electronic trip units (e.g. Micrologic 5, 6). Electronic trip units (e.g. Micrologic 5, 6 ). (1) Ir is the thermal protection threshold (sometimes written Ith) of thermal-magnetic trip units or the long-delay protection threshold of electronic trip units. These thresholds are defined by an inverse time curve that depends on the selected setting. (2) tr is the time delay of the long-delay thermal protection for a given value of Ir. (3) Im is the magnetic threshold of thermal-magnetic trip units and Isd the short-delay threshold of electronic trip units. (4) tm is the time delay (adjustable or fixed) of the magnetic protection of thermal-magnetic trip units and tsd the time delay (generally adjustable) of the short-delay protection of electronic trip units. (5) Ii is the instantaneous tripping threshold. APC by Schneider Electric 05/2009 edition ch. 1 - p. 35 Protection (cont.) Fig. 1.31. Circuit-breaker time/current curves (Icu is the ultimate breaking capacity). APC by Schneider Electric 05/2009 edition ch. 1 - p. 36 Protection (cont.) Discrimination, cascading, current limiting Discrimination Discrimination results from correct circuit-breaker selection and setting such that, if a fault occurs, it trips only the first upstream circuit breaker. Discrimination thus limits the part of the installation affected by the fault to a strict minimum. There are a number of types of discrimination summed up in the table below and illustrated on the previous page. Current limiting When a high fault current hits the circuit breaker, the breaker contacts separate under the electrodynamic forces, an arc is created and its resistance limits the shortcircuit energy. Cascading When a short-circuit occurs downstream of the installation (see fig. 1.32), the fault current also flows through the upstream circuit breaker which current limits, thus attenuating the current applied to the downstream circuit breaker. The breaking capacity of the latter is thus reinforced. Discrimination Current discrimination Concerns All types of trip units Principle The fault current is lower than the upstream threshold setting. Ir upstream > Ir downstream and Im or Isd upstream > Im or Isd downstream Delays upstream tripping by the long-time (Ir) and short-time (Im or Isd) delay. Time discrimination Electronic trip units only (e.g. Micrologic) Compact NSX Arc pressure upstream is not sufficient to trip Energy and NS the upstream circuit breaker, but it is discrimination sufficient to trip the downstream circuit breaker. Delays upstream tripping if the short-circuit Compact Zone-selective is also detected downstream. NSX 100 to interlocking Masterpact with A pilot wire connects the upstream and downstream trip units. Micrologic trip units Fig. 1.32. Upstream/downstream discrimination and cascading. APC by Schneider Electric 05/2009 edition ch. 1 - p. 37 Protection (cont.) Selection of circuit breakers Rating The selected rating (rated current) for the circuit breaker must be the one just above the rated current of the protected downstream cable. Breaking capacity The breaking capacity must be selected just above the short-circuit current that can occur at the point of installation. Ir and Im thresholds The table below indicates how to determine the Ir and Im thresholds to ensure discrimination, depending on the upstream and downstream trip units. Remark. Time discrimination must be implemented by qualified personnel because time delays before tripping increase the thermal stress (I2t) downstream (cables, semiconductors, etc.). Caution is required if tripping of CB2 is delayed using the Im threshold time delay. Energy discrimination does not depend on the trip unit, only on the circuit breaker. Ir and Im thresholds depending on the upstream and downstream trip units Type of downstream Ir upstream / Ir circuit downstream ratio downstream trip unit all types distribution > 1.6 asynchronous motor >3 Im upstream / Im Im upstream / Im downstream ratio downstream ratio magnetic >2 >2 electronic > 1.5 > 1.5 Special case of generator short-circuits Figure 1.33 shows the reaction of a generator to a short-circuit. To avoid any uncertainty concerning the type of excitation, we will trip at the first peak (3 to 5 In as per X"d) using the Im protection setting without a time delay. Fig. 1.33. Generator during a short-circuit. APC by Schneider Electric 05/2009 edition ch. 1 - p. 38 Protection (cont.) Example Consider the example used to determine the UPS power rating (Ch. 1 p. 21) with a number of parallel-connected 400 V three-phase loads, namely: Computer system - S1 = 4 x 10 kVA, = 0.6, in-rush current 8 In over four periods (80 ms), Variable-speed drive - S2 = 20 kVA, = 0.7, in-rush current 4 In over five periods (100 ms), Isolation transformer - S3 = 20 kVA, = 0.8, in-rush current 10 In over six periods (120 ms). The three loads represent 54 kW with a power factor of 0.68. In chapter 1, p. 21, an MGE Galaxy PW was selected, with a power rating of 100 kVA, I = 100 / (400 x 3 ) = 144 A. 630 kVA transformer 400 kVA generator Determine CB1 and CB2 Rated apparent output power 100 kVA In = 144 A Power factor at UPS output for all loads = 0.68 Determine the most powerful CB3 for discrimination Total power consumed by the loads P (kW) = 54 kW 40 kVA = 0.6 Fig 1.34. Example of an installation. 20 kVA = 0.7 20 kVA cos = 0.8 Maximum active output power (that the UPS can supply to the loads) Sn (kVA) = 68 kW The goal is to select circuit breakers CB1 and CB2, and the most powerful circuit breaker CB3 compatible with discrimination requirements, given that the upstream installation includes the following: 20 kV / 400 V transformer with a power rating of 630 kVA, 400 V engine generator set with a power rating of 400 kVA, Transformer to MLVS link, five meters of aluminium cable 4 x 240 mm2 per phase, Busbars to circuit breaker link, four meters using three copper bars 400 mm² per phase. Calculation of CB1 and CB2 ratings and breaking capacities The breaking capacity depends on the short-circuit currents downstream of CB1 and CB2 at the level of the main low-voltage switchboard (MLVS). Most often, this upstream short-circuit value is supplied by the utility. It can also be calculated. It is necessary to determine the sum R of the resistances upstream and the sum X of the reactances upstream of the considered point. The three-phase short-circuit current is calculated as: U Isc 3-ph = 3 R2 X 2 U is the phase-to-phase no-load voltage (load voltage + 3 to 5%). R = Rupstream and X = Xupstream In this example, we simply indicate the general method with a number of simplifications to shorten the calculations. For more detailed information, see the Cahier Technique document no. 158 "Calculation of short-circuit currents" from Schneider Electric. APC by Schneider Electric 05/2009 edition ch. 1 - p. 39 Protection (cont.) Upstream system Ra, Xa Sources Rtr Xtr Source output to MLVS cable link Rc, Xc General circuit breaker Rd, Xd MLVS busbars Rb, Xb Fig. 1.35. Calculation of short-circuit current for CB1 and CB2. It is necessary to calculate the resistances and reactances upstream of CB1 and CB2 in figure 1.34. Distribution system upstream of the transformer Psc = upstream short-circuit power = 500 MVA = 500 x 106 VA U20 = phase-to-phase no-load voltage on the transformer secondary winding = 400 V, + 3%, i.e. 410 V Rup = resistance upstream 15% Xup, negligible given Xup Xup = reactance upstream with respect to transformer secondary winding Xup = 410 2 U20 2 = 0.288 m = Psc 500 x 10 6 Rup 0 and Xup = 0.33 m. Transformer Sn = rated apparent power 630 kVA In = rated current = 630 / U 3 = 630 103 / (400 x Usc = transformer short-circuit voltage = 4% Pcu = transformer copper losses in VA Rtr = transformer resistance = Pcu 3 In2 Xtr Ztr = transformer impedance = Rtr 0 and 3 ) = 909 A 20% Xtr, negligible given Ztr U20 2 x Usc = 4102 x 0.04 / 630 103 = 10.7 m Sn Xtr = 10.7 m. Cables linking the transformer to the MLVS Length 5 meters Cross-section 240 mm² = resistivity at the normal temperature of the conductors copper: = 22.5 m.mm2/m, aluminium: = 36 m.mm2/m Xc = conductor reactance (typically 0.08 m/m) = 0.08 x 5 = 0.4 m L = 22.5 x 5 / (4 x 240) = 0.12 m Rc = cable resistance (copper) = S Rc = 0.12 m and Xc = 0.4 m. General circuit breaker Typical values Rd 0 et Xd = 0.15 m. APC by Schneider Electric 05/2009 edition ch. 1 - p. 40 Protection (cont.) Busbars Xb = busbar reactance (typically 0.15 m/m) = 0.15 x 4 = 0.6 m Rb = busbar resistance = L / S= 22.5 x 4 / (3 x 400) = 0.075 m (negligible) Rb 0 and Xb = 0.6 m. Transformer Isc at the level of CB1 and CB2 R = Total upstream resistance = 0.12 m X = Total upstream reactance = 0.33 + 10.7 + 0.4 + 0.15 + 0.6 =12.18 m R can be neglected, given X. U U Isc 3-ph = 2 2 3 X 3 R X 410 3 x 12.18 x 10 3 = 19.4 kA Note. A rough estimate is provided by the short-circuit current on the transformer terminals, assuming that the upstream short-circuit power is infinite. ISCT = on transformer terminals = In / Usc = 20 In = 20 x 909 = 18.2 kA Generator Isc at the level of CB1 and CB2 rated apparent power of the generator = 400 kVA rated current of the generator = 400 / U 3 = 400 103 / (400 x X"d = short-circuit voltage of the generator = 10% 3 ) = 577 A It is decided to trip at 5 In (see fig. 1.33). ISCG = on the generator terminals = 5 In = 5 x 577 = 2.9 kA Continuous current of CB1 This is the current at the UPS input. It is necessary to multiply the UPS rating by 1.2 to take into account the efficiency, i.e. 120 kVA. Iinput = 120 / U 3 = 120 103 / (400 x 3 ) = 173 A Continuous current of CB2 This is the continuous current of the loads supplied via the bypass, i.e. 54 kW with a power factor of 0.68 for an apparent power S = 54 / 0.68 = 67.5 kVA. Iload = 67.5 / U 3 = 120 103 / (400 x 3 ) = 97 A Energising current of the largest load The loads must be energised at different times. The highest inrush current is that of the 20 kVA transformer, i.e. In = 28.8 A and 10 In = 288 A - 120 ms. Calculation of the maximum static-switch current This is the short-circuit current at the level of CB3, which is practically that of CB2. Selection parameters The table below sums up the various values calculated. Parameter transformer short-circuit current generator short-circuit current rectifier current (UPS input) continuous load current downstream of the UPS energising current of the largest load maximum static-switch current Value 19.4 kA 2.9 kA 173 A 97 A 288 A - 120 ms 19.4 kA Characteristics of CB1 and CB2 Characteristic Breaking capacity Continuous current Ir threshold Im threshold D1 D2 > 19.4 kA, i.e. 25 kA > 19.4 kA, i.e. 25 kA > 173 A, i.e. 200 A > 97 A, i.e. 125 A > 173 A +20% > 97 A + 20% > 173 A + 20% and > 288 A +20% and < 2.9 kA - 20% < 2.9 kA - 20% 20% represents here the typical tolerance range of circuit-breaker settings. APC by Schneider Electric 05/2009 edition ch. 1 - p. 41 Protection (cont.) Characteristics of the most power circuit breaker CB3 possible Sources Incomer circuit breakers (input) Static bypass Negligible impedance Outgoing circuit breakers (output) Isc at CB3 Isc at CB2 Fig. 1.36. Calculation of the short-circuit current at CB3. Operation with bypass power Breaking capacity The highest short-circuit current downstream of CB3 is virtually that of CB2 because it is assumed that the outgoing circuits are near the UPS. Consequently, the breaking capacity of CB3 is also 25 kA. The rating is determined by the largest load, i.e. the 4 x 10 kVA of the computer system with a continuous current of: Iload = 40 / U 3 = 40 103 / (400 x 3 ) = 57 A A 60 A device should be selected. Settings A majority of the loads is of the distribution type, i.e. the Ir threshold of CB3 must be less than 97 A / 1.6, i.e. < 61 A. The Im threshold must be less than 1847 / 2, i.e. < 900 A. Operation without bypass power In this case, the short-circuited UPS limits its current to 2.33 In for one second. For APC by Schneider Electric UPSs of the MGE Galaxy range, experimental results have determined that the highest rating of CB3 must be less than 0.5 In to ensure discrimination. This is the case for the circuit breaker for the computer loads. 60 A < 0.5 x 144= 72 A APC by Schneider Electric 05/2009 edition ch. 1 - p. 42 Cables Selection of cable sizes Cable temperature rise and voltage drops The cross section of cables depends on: permissible temperature rise, permissible voltage drop. For a given load, each of these parameters results in a minimum permissible cross section. The larger of the two must be used. When routing cables, care must be taken to maintain the required distances between control circuits and power circuits, to avoid any disturbances caused by HF currents. Temperature rise Permissible temperature rise in cables is limited by the withstand capacity of cable insulation. Temperature rise in cables depends on: the type of core (Cu or Al), the installation method, the number of touching cables. Standards stipulate, for each type of cable, the maximum permissible current. Voltage drops Maximum values The maximum permissible voltage drops are: 3% for AC circuits (50 or 60 Hz), 1% for DC circuits. Selection tables The tables below indicate the voltage drop in percent for a circuit made up of 100 meters of copper cable. To calculate the voltage drop in a circuit with a length L, multiply the value in the table by L/100. If the voltage drop exceeds 3% on a three-phase circuit or 1% on a DC circuit, increase the cross section of the conductors until the value is within tolerances. Voltage drop for 100-meter cables Sph - the cross section of the conductors In - rated current of the protection devices on the circuit Three-phase circuit (copper conductors) 50-60 Hz - 400 V three phase, cos = 0.8, balanced 3-ph + N system 2 Sph (mm ) 10 16 25 35 50 70 95 120 150 0.9 In (A) 10 1.2 16 1.6 1.1 20 2.0 1.3 0.9 25 2.6 1.7 1.1 32 3.3 2.1 1.4 1.0 40 4.1 2.6 1.7 1.3 1.0 50 5.1 3.3 2.2 1.6 1.2 0.9 63 5.7 3.7 2.4 1.7 1.3 1.0 0.8 70 6.5 4.2 2.7 2.1 1.5 1.2 0.9 0.7 80 5.3 3.4 2.6 2.0 2.0 1.1 0.9 0.8 100 8.2 6.6 4.3 3.2 2.4 2.4 1.4 1.1 1.0 125 5.5 4.3 3.2 3.2 1.8 1.5 1.2 160 5.3 3.9 3.9 2.2 1.8 1.6 200 4.9 4.9 2.8 2.3 1.9 250 3.5 2.9 2.5 320 4.4 3.6 3.1 400 4.5 3.9 500 4.9 600 800 1000 For a three-phase 230 V circuit, multiply the result by 3 . For a single-phase 208/230 V circuit, multiply the result by 2. APC by Schneider Electric 05/2009 edition 185 0.8 1.1 1.3 1.7 2.1 2.7 3.4 4.2 5.3 240 300 0.9 1.2 1.4 1.9 2.3 2.9 3.6 4.4 6.5 0.9 1.2 1.5 1.9 2.4 3.0 3.8 4.7 ch. 1 - p. 43 Cables (cont.) DC circuit (copper conductors) 2 Sph (mm ) 25 In (A) 100 5.1 125 160 200 250 320 400 500 600 800 1000 1250 35 3.6 4.5 50 2.6 3.2 4.0 70 1.9 2.3 2.9 3.6 95 1.3 1.6 2.2 2.7 3.3 120 1.0 1.3 1.6 2.2 2.7 3.4 150 0.8 1.0 1.2 1.6 2.2 2.7 3.4 185 0.7 0.8 1.1 1.3 1.7 2.1 2.8 3.4 4.3 240 0.5 0.6 0.6 1.0 1.3 1.6 2.1 2.6 3.3 4.2 5.3 300 0.4 0.5 0.7 0.8 1.0 1.3 1.6 2.1 2.7 3.4 4.2 5.3 Special case for neutral conductors In three-phase systems, the third-order harmonics (and their multiples) of singlephase loads add up in the neutral conductor (sum of the currents on the three phases). For this reason, the following rule is applied - neutral cross section = 1.5 x phase cross section. Calculation example Consider a 70-meter 400 V three-phase circuit, with copper conductors and a rated current of 600 A. Standard IEC 60364 indicates, depending on the installation method and the load, a minimum cross section. We shall assume that the minimum cross section is 95 mm2. It is first necessary to check that the voltage drop does not exceed 3%. The table for three-phase circuits on the following page indicates, for a 600 A current flowing in a 300 mm2 cable, a voltage drop of 3% for 100 meters of cable, i.e. for 70 meters: 3 x 70/100 = 2.1%, less than the 3% limit. A identical calculation can be run for a DC current of 1000 A in a 10-meter cable with a cross section of 240 mm². The voltage drop for 100 meters is 5.3%, i.e. for ten meters: 5.3 x 10/100 = 0.53%, less than the 1% limit. Example of an installation Fig. 1.37. Connection of cables. APC by Schneider Electric 05/2009 edition ch. 1 - p. 44 Energy storage Storage technologies Energy storage in UPSs UPSs require an energy-storage system to supply the inverter with power if utility power fails or is no longer within tolerances. The stored energy must have the following characteristics: electricity that is immediately available to ride through micro-breaks, short voltage drops and utility outages, sufficient power level to supply the entire load, i.e. a rating equivalent to that of the UPS system itself, backup time, generally about ten minutes, suited to the needs of the loads and to any other sources available (e.g. an engine generator set for long backup times). Fig. 1.38. Simplified diagram of a UPS with backup energy storage. Available technologies The various technologies currently available are the following: batteries: - sealed lead-acid, - vented lead-acid, - nickel cadmium, ultracapacitors, flywheels: - traditional units turning at low speeds (1500 rmp) and combined with engine generator sets, - medium-speed (7000 rpm) or high-speed (30 to 100 000 rpm) units. Comparison of technologies See WP 65 Batteries are by far the most commonly employed solution today. They are the dominant solution due to low cost, proven effectiveness and storage capacity, but nonetheless have a number of disadvantages in terms of size, maintenance and the environment. Ultracapacitors do not yet offer the necessary performance levels. Flywheels operating at high speeds constitute a possible technology in terms of their power ratings (40 to 500 kW), for short backup times (12 seconds to 1 minute). Figure 1.39 shows the fields of application for the different technologies. For more information, see White Paper WP 65: "Comparing Data Center Batteries, Flywheels, and Ultracapacitors". Fig. 1.39. Characteristics in terms of power ratings and backup times. APC by Schneider Electric 05/2009 edition ch. 1 - p. 45 Energy storage (cont.) The table below compares the different solutions in terms of their capacity to meet the energy-storage requirements of static UPSs. Criteria for comparison Technology Sealed lead-acid Vented lead-acid Ni/Cad batteries Ultracapacitors Flywheels batteries batteries Power **** **** Backup time *** 5 minutes up to several hours **** low *** no * ** ** *** Purchase price Implementation / installation / start-up Requires a special room Temperature Service life Footprint Maintenance Frequency / time required Maturity of the technology for UPSs **** * *** **** * * ** 5 minutes up to several hours 5 minutes up to several dozen minutes a few seconds a few dozen seconds *** ** * * low to medium high cost multiplied by 2 or 3 compared to batteries, for 10 seconds of backup time cost multiplied by 8 compared to batteries, for 10 seconds of backup time ** * **** ** yes yes no yes * ** ** ** ** *** ** * **** **** **** **** *** *** *** * low medium high none long servicing times **** **** **** ** *** **** excellent *** good ** fair * poor Flywheels APC by Schneider Electric offers flywheel energy storage systems on request. This solution is suitable to complement batteries in that it may be used to ride through short disturbances without calling on battery power, thus preserving the battery. Use without a battery is possible, but the backup time is only a dozen seconds. For certain applications, such a short backup time is insufficient to start an engine generator set. Selection of a battery Types of batteries The batteries most frequently used in UPSs are: sealed lead-acid, also called gas-recombination batteries, vented lead-acid, nickel cadmium. Lithium-polymer batteries are currently being studied for use in UPSs. Solutions using this technology should be available in two to three years. Types of batteries, see Ch. 5 p. 32 "Energy storage - Types of batteries". For use in conjunction with its UPS ranges, APC by Schneider Electric recommends sealed lead-acid batteries. Selection of a battery depends on the following factors: operating conditions and requirements (special room, battery cabinet, racks, etc.), required backup time, cost considerations. Backup time APC by Schneider Electric offers: standard backup times of 5, 10, 15 or 30 minutes, custom backup times that can reach a number of hours. Selection depends on: the average duration of power-system failures, any available sources offering long backup times (engine generator set, etc.), the type of application. APC by Schneider Electric 05/2009 edition ch. 1 - p. 46 Energy storage (cont.) The following general rules apply. Computer systems Battery backup time must be sufficient to cover file-saving and system-shutdown procedures required to ensure a controlled shutdown of the computer system. Generally speaking, the computer department determines the necessary backup time, depending on its specific requirements. Industrial processes The backup-time calculation should take into account the economic cost incurred by an interruption in the process and the time required to restart. Applications requiring long backup times An engine generator set can back up a battery if long outages occur, thus avoiding the need for very large batteries. Generally speaking, use of an engine generator set becomes feasible for backup times greater than 30 minutes to one hour. The combination must be carefully studied to optimise the generator rating and ensure correct operation. Combination with an engine generator set, see Ch. 5 p. 35 "Engine generator set". Service life APC by Schneider Electric offers batteries with service lives of 5 or 10 years, or longer. Battery service life, see Ch. 5 p. 33. Comparison between types of batteries Sealed lead-acid batteries (gas-recombination) These are the most commonly used batteries for the following reasons: no maintenance, easy implementation, installation in all types of rooms (computer rooms, technical rooms not specifically intended for batteries, etc.). Vented batteries This type of battery (lead-acid or Ni/Cad) offers certain advantages: long service life, long backup times, high power ratings. Vented batteries must be installed in special rooms complying with precise regulations (see Ch. 1 p. 51 "Preliminary work") and require appropriate maintenance. UPSs from APC by Schneider Electric include advanced battery-monitoring systems. Battery monitoring Battery monitoring on MGETM GalaxyTM UPSs DigiBatTM The DigiBatTM battery-monitoring system is an assembly of hardware and software, installed as standard on UPSs of the MGE Galaxy range from APC by Schneider Electric and offering the following functions: automatic entry of battery parameters, optimised battery service life, protection against excessive discharges, regulation of the battery floating voltage depending on the temperature, limitation of the battery current, continuous evaluation of available power taking into account the battery age, the temperature and the percent load, forecast of battery service life, periodic, automatic tests on the battery, including a check on the battery circuit, an open-circuit test, a partial-discharge test, etc. DigiBat, see Ch. 5 p. 34 "Battery Management". APC by Schneider Electric 05/2009 edition ch. 1 - p. 47 Energy storage (cont.) Environment sensor unit Battery operating parameters and particularly the temperature affect battery life. The Environment Sensor, easy to install and combined with a Network Management card (SNMP/Web), makes possible monitoring of temperature/humidity and the status of two contacts via SNMP or the web. It also initiates equipment shutdown if necessary. Detection and prevention of battery failure for MGETM GalaxyTM UPSs In spite of the advantages of sealed lead-acid batteries, over time, all batteries will fail due to ageing. Without rigorous monitoring, the true integrity and capacity of a battery remains unknown. Battery-monitoring techniques have a major impact on reliability and can be used to define the best strategy for replacement, resulting in a better level of protection. APC by Schneider Electric also offers continuous, cell by cell, battery-monitoring systems with software and communication capabilities. These systems can be implemented by the user or integrated in the Teleservice offer. B2000 battery-monitoring system The B2000 system offers continuous, overall monitoring of the main battery parameters. That includes the voltage, current, temperature and any drift detected during charge and discharge cycles. It issues an alarm when tolerance levels are overrun. Automatic recording of discharges, whether planned or unplanned, is also available for data analysis. The monitoring system can help detect possible problems before the battery fails and thus enhance availability of UPS energy. Cellwatch battery-monitoring system General battery maintenance may not be sufficient to ensure correct operation, notably for mission-critical applications where there is no room for error. Between periodic tests (generally once every three months), a cell may suddenly fail. A valve-regulated sealed lead-acid cell can fail in just a few days after a periodic test. The cause is the chemical reactions that take place in the cell following charge and discharge cycles. These cycles occur even if the protection system is not in operation. What is more, corrosion can affect the entire connection system of the battery string, inside or outside of the cell. It was therefore necessary to do more than simply check the voltage. The research carried out showed that the internal resistance or the impedance of the cell is a good indicator of its status, in that it reveals both deterioration and any physical problems. The Cellwatch monitoring system uses this system based on cell impedance to monitor each cell. It provides reliable monitoring of the service life of each cell. APC battery management system for SymmetraTM UPSs The APC battery management system, available for UPSs of the Symmetra range from APC by Schneider Electric, ensures your batteries are optimally charged and ready for use. This browser-accessible, 1U rackmountable system combines battery monitoring and testing with individual boost charging for peak battery performance. Integration into your preferred building management system or use of a Web browser provides visibility of the health and status of your batteries. This system makes it possible to solve battery problems before they affect availability. APC by Schneider Electric 05/2009 edition ch. 1 - p. 48 Human-machine interface and communication Human-machine interface (HMI) General characteristics The human-machine interface on the UPS must be user-friendly, easy to use and multi-lingual (adjustable to the user's language). It is generally made up of a mimic panel, a status and control panel, and an alphanumeric display. A password-protected personalisation menu may be available for entry of installation parameters and access to detailed information. Example The HMI typically offers the functions listed below. On and Off buttons delayed to avoid erroneous operations. with an option for a remote EPO (emergency power off). independent with respect to the rest of the display Status LEDs that clearly identify: normal operation (load protected), downgraded operating mode (malfunction), dangerous situations for the load (load not protected), operation on battery power. Alarms alarm buzzer and buzzer reset button. battery shutdown warning. general alarm. battery fault. A screen providing: access to measurements - input power (voltage, current, frequency). - battery (voltage, charge and discharge currents, remaining backup time, temperature). - inverter output (phase-to-neutral voltage, current, frequency, active and apparent power, crest factor). access to history logs - log containing time-stamped events. - curves and bargraphs of the measured values. Communication High availability for critical applications requires communicating protection equipment The UPS system, essential for mission-critical equipment, must include communication features that keep operators continously informed, wherever they may be, of any risk of compromising the operating security of the system so that they can take immediate action. To ensure power availability, the UPS communication features provide the following four essential functions: Supervision / monitoring of all installed UPSs via software. Notification via the network and the Internet. Controlled shutdown (local or remote, automatic or manual) of protected applications. Teleservice via a modem and telephone line to a support centre. APC by Schneider Electric Edition 05/2009 ch. 1 - p. 49 Human-machine interface and communication (cont.) APC by Schneider Electric solutions Communication cards Network Management Card (Ethernet) - Web monitoring - Email notification - SNMP MIB & Traps - Server protection with Network Shutdown Module - Supervision with Enterprise Power Manager or ISX Central - Environment monitoring with Environment Sensor (T°, H%, Inputs) Modbus – Jbus card (RS232 & RS485) - Monitoring Teleservice card (Modem) - Alerts - Monitoring - Diagnostics - Reporting Relay card (contacts) - Indications Management software Enterprise Power Manager & ISX Central (software & server) Software solutions to manage all installed UPSs via IP networks, web compatible and accessible from any web browser. NMS Integration kits (Network Management System) Integration in NMSs such as HP OpenView, IBM Tivoli, CA Unicenter, etc. Network Shutdown Module - Software module for safe system shutdown. Fig. 1.40. The communication cards combined with supervision software offer a wide range of functions. APC by Schneider Electric 05/2009 edition ch. 1 - p. 50 Preliminary work Installation considerations The main elements that must be taken into account for the UPS installation are the following: plans for site modifications, any preliminary work (notably for a battery room), taking into account: - the dimensions of equipment, - operating and maintenance conditions (accessibility, clearances, etc.), - temperature conditions that must be respected, - safety considerations, - applicable standards and regulations, ventilation or air-conditioning of rooms, creation of a battery room. Dimensions Layout of UPS cabinets and enclosures should be based on precise plans. The physical characteristics of UPSs from APC by Schneider Electric that may be used to prepare the plans are presented in chapter 4. They indicate, for each range: the dimensions and weights of: - UPS and centralised-bypass cabinets; - battery cabinets, - any auxiliary cabinets (autotransformers, transformers, filters, etc.), minimum clearances required for cabinets and enclosures to ensure optimal ventilation and sufficient access. Ventilation, air-conditioning Ventilation requirements UPSs are designed to operate within a given temperature range (0 to 40°C for UPSs from APC by Schneider Electric ) that is sufficient for most operating conditions without modifications. However, UPSs and their auxiliary equipment produce heat losses that can, if no steps are taken, increase the temperature of a poorly ventilated room. What is more, the service life of a battery is heavily dependent on the ambient temperature. The service life is optimal for temperatures between 15° C and 25° C. This factor must be taken into account if the battery is installed in the same room as the UPS. A further consideration is the fact that UPSs may be installed in the same room as computer equipment which often has more severe requirements concerning operating-temperature ranges. Selecting a type of ventilation For all the above reasons, a minimum amount of ventilation is required, and where applicable air-conditioning, to avoid any risk of excessive temperature rise in the room due to the heat losses. Ventilation can be by: natural convection, forced exchange by a ventilation system, installation of an air-conditioning unit. Selection depends on: the heat losses that must be evacuated, the size of the room. The thermal characteristics of UPSs from APC by Schneider Electric are indicated in chapter 4 and may be used to calculate ventilation needs. They mention for each range: the heat losses of cabinets and any filters installed, the volume of air output by a ventilation system. APC by Schneider Electric 05/2009 edition ch. 1 - p. 51 Preliminary work (cont.) IP degree of protection and noise level Degree of protection (IP) UPSs must operate in an environment that is compatible with their degree of protection (IP 20 for UPSs from APC by Schneider Electric), defined by standard IEC 60529/EN 60529. The presence of dust, water and corrosive substances must be avoided. Noise level UPSs must produce a low level of noise, suited to the room where they are installed. Measurement conditions for the level of noise indicated by the manufacturer must comply with standard ISO 3746 (measurement of noise). Battery room Where possible and if desired, the battery should be installed in a cabinet. Battery-cabinet dimensions are indicated for each UPS range, depending on the rated power. However, for very high-power UPSs, batteries are generally installed in special rooms (electrical room). Batteries must be installed in compliance with international standards, local regulations and standard IEC 60364. Battery installation method The criteria determining the battery-installation method are the following: available floor space, the weight that the floor can handle (kg/m2), ease of access and maintenance. The following three methods are used. Battery installed directly on floor This is the most simple arrangement. However, a large battery room is required, given: the large amount of floor space occupied by the battery, the insulated flooring (duck board), which is mandatory if the voltage exceeds 150 volts. Battery on racks The battery cells are installed on a number of different levels, off the floor. When determining the height between each rack, it is necessary to take into account the space required to check battery levels and fill the battery cells easily. A minimum height of 450 mm is recommended. Battery on tiers This installation method is similar to the preceding. It is the most convenient method for checking battery levels. Battery-room features Whatever the installation method selected, the battery installation must comply with the following requirements (the numbers indicate the elements shown in figure 1.40). Floor and walls (1) The floor must slope to an evacuation trough which leads to a holding tank. Protection coating against acid on the floor and walls, up to a height of at least 0.5 meters. For example, asphalt for lead-acid batteries, PVC or chlorine-based paint for alkaline batteries. APC by Schneider Electric 05/2009 edition ch. 1 - p. 52 Preliminary work (cont.) Ventilation (2) calculation of throughput The volume of air to be evacuated depends on the maximum load current and the type of battery. In installations comprising a number of batteries, the quantities of air that must be evacuated are cumulative. - vented batteries d = 0.05 x N x Im, where d - throughput in cubic meters per hour, N - number of battery cells, Im - maximum load current in amperes. - sealed battery The ventilation conditions in a general-purpose room are sufficient. safety An automatic device must stop battery charging if the ventilation system fails. location Air must be drawn out from the top of the battery room. Layout of cells (3) Layout must inhibit simultaneous contact with two bare parts presenting a voltage greater than or equal to 150 V. If the above condition cannot be met, terminal shields must be installed and connections must be made using insulated cables. Service flooring (4) If the voltage exceeds 150 V, special flooring is required. It must offer sure footing, be insulated from the floor and offer at least one meter of walkway around the battery. Battery connection (5) Connections must be as short a possible. Battery-protection circuit breaker (6) The circuit breaker is generally installed in a wall-mounted enclosure. Fire-fighting equipment (7) Authorized fire extinguishers include power, CO2 or sand. Safety equipment (8) The safety equipment must include protective glasses, gloves and a source of water. Inspection equipment (9) Hydrometer. Filling device. Thermometer. Sensors (10) Hydrogen detector. Temperature sensor. Fig. 1.41. Layout of battery room. APC by Schneider Electric 05/2009 edition ch. 1 - p. 53 APC by Schneider Electric 05/2009 edition ch. 1 - p. 54 Chapter 2. Selection of the UPS configuration Contents Types of possible configurations ..................................2-2 Selection table and corresponding ranges...................2-5 Diagram no. 1 ..................................................................2-6 Single UPS Diagram no. 2 ..................................................................2-7 Active redundancy with two integrated parallel UPS units Diagram no. 3 ..................................................................2-8 Active redundancy with integrated parallel UPS units and external maintenance bypass Diagram no. 4 ..................................................................2-9 Isolated redundancy with two UPS units Diagram no. 5 ..................................................................2-10 Active redundancy with parallel UPS units and centralised static-switch cubicle (SSC) Diagram no. 6 ..................................................................2-11 Active redundancy with parallel UPS units and total isolation, single busbar Diagram no. 7 ..................................................................2-12 Active redundancy with parallel UPS units and total isolation, double busbar Diagram no. 8 ..................................................................2-13 Active redundancy with parallel UPS units, double SSC and total isolation, single busbar Diagram no. 9 ..................................................................2-14 Active redundancy with parallel UPS units, double SSC and total isolation, double busbar Diagram no. 10 ................................................................2-15 Isolated redundancy with N+1 UPS units Diagram no. 11 ................................................................2-16 Redundant distribution with static transfer switch (STS) Diagram no. 12 ................................................................2-18 Redundant distribution with static transfer switch (STS) and PDU APC by Schneider Electric 05/2009 edition ch. 2 - p. 1 Types of possible configurations Basic diagrams Single source The load is supplied by a single set of UPSs. Multi-source The load is supplied by more than one set of UPSs. Fig. 2.1. Basic diagrams. UPS configurations Single UPS This is the standard double-conversion UPS (see fig. 2.2). Single UPSs can be used to form redundant configurations as shown in diagrams 4 and 11. Single UPS, see Ch. 1 p. 9 and Ch. 4 p. 14 "UPS components and operation". Standard diagrams: No. 1 No. 4 No. 11 Fig. 2.2. Double-conversion single UPS. Parallel UPS Purpose of parallel connection Parallel connection of a number of identical UPS units is the means to: increase the power rating, establish redundancy that increases MTBF and availability, make the installation scalable. TM TM Two types of MGE Galaxy UPS units can be connected in parallel: integrated parallel UPS units: each UPS unit includes an automatic bypass and a manual maintenance bypass (fig. 2.2). The manual bypass may be common to the entire system and located in an external cubicle (e.g. fig. 2.3). parallel UPS units with a centralised static-switch cubicle (SSC) (e.g. fig. 2.4). Modular UPS TM UPSs of the Symmetra range are true modular parallel systems. They are made up of dedicated and redundant modules (power, intelligence, battery and bypass), all engineered into a design that is easily and efficiently serviceable and scalable. Identical plug-in power modules can be easily added in parallel as demand grows or as higher levels of availability are required (e.g. up to four 16 kW modules for Symmetra PX 48 with N+1 redundancy). The modules are hot-swappable. Modular design with plug-in power modules improves dependability, in particular maintainability and availability, as well the upgradeability of the installation. APC by Schneider Electric 05/2009 edition ch. 2 - p. 2 Types of possible configurations (cont.) MGETM GalaxyTM parallel UPSs Integrated parallel UPSs This configuration is upgradeable, starting for instance with one integrated parallel UPS unit equipped with an automatic bypass and a manual maintenance bypass. When starting with two units or when expanding to two units or more, a common maintenance bypass is installed in an external enclosure (see fig. 2.3). Standard diagrams: No. 2 No. 3 Fig. 2.3. Installation with three integrated parallel UPS units and a common maintenance bypass. Parallel UPS units with a centralised static-switch cubicle (SSC) The static-switch cubicle comprises an automatic bypass and a maintenance bypass that are common for a number of modules without a bypass (see fig. 2.4). It is possible to have two redundant SSCs. Upgrading of this configuration depends on the rating of the static switch. It offers the highest level of reliability (SSC with independent UPS units). Standard diagrams: No. 5 No. 6 No. 7 No. 8 No. 9 Fig. 2.4. Three parallel UPS units with a centralised static-switch cubicle (SSC). APC by Schneider Electric 05/2009 edition ch. 2 - p. 3 Types of possible configurations (cont.) Parallel connection with redundancy The parallel configurations presented above may or may not be redundant. Without redundancy All the UPS units are required to supply the load. Failure of one unit means the entire system shuts down. With active redundancy (N+1, N+2, etc.) Only N UPS units are required to supply the load, even though N+1, N+2 or more units are installed. This ensures a secure supply of power to the load even if one (for N+1 redundancy) or two (for N+2 redundancy) UPS units fail or require maintenance. Optimum redundancy of non-modular UPSs For non-modular systems, differences in the lengths or tightening torques of cables connecting the different units can lead to problems concerning the impedance upstream and downstream of each UPS. For this reason, the highest MTBF is obtained for redundant systems with just two UPSs (fig. 2.5). For modular UPS systems, module interconnections are an integral part of the system, thereby eliminating installation problems that can lower the MTBF as more units are added. Fig. 2.5. For non-modular redundant UPS systems, the best MTBF is obtained with two units. Redundant distribution with an STS All the loads are supplied by more than one UPS source (two single UPS units in figure 4.5). Each source can be made up of a number of parallel-connected units offering active redundancy. Use of a static transfer switch (STS) ensures transfer of the load between the sources in the event of a downstream fault (while avoiding any risk of fault propagation) or for maintenance. Power distribution units (PDUs) can be used to complete this distribution configuration, offering: load management, multi-channel supply of power to the loads (dual attach), isolation of parts of the installation for maintenance or upgrading. This type of configuration ensures a very high degree of availability and offers a number of installation-upgrade possibilities. Standard diagrams: No. 11 No. 12 Fig 2.6. Redundant distribution with an STS. APC by Schneider Electric 05/2009 edition ch. 2 - p. 4 Selection table and corresponding ranges Criteria for comparison The table below compares the standard diagrams of this chapter, mainly related to MGETM GalaxyTM UPSs, according to the following criteria. Availability A level of availability meeting the needs of the application. Figures are based on: an estimated level of utility-power availability of 99.9% (the European average), an MTTR of ten hours as per standard MIL-HDB-217-F level 2 (U.S. military) and IEEE. Maintainability Ensure easy maintenance of the equipment under safe conditions for personnel and without interrupting operation. Upgradeability It must be possible to upgrade the installation over time, taking into account both the need to expand the installation gradually and operating requirements. Discrimination and non propagation of faults It must be possible to limit faults to as small a part of the installation as possible, while enabling servicing without stopping operations. Installation operation and management Make operations easier by providing the means to anticipate events via installation supervision and management systems. Single-source configurations Standard Criteria for comparison diagram number Availability MTBF Maintainability Upgradeability Comment 1. Single UPS 99.99790% M1=475 000 h * 4 parallel-connected Reference for UPS units calculations 2. 2 integrated 99.99947% up to 4 x M1 ** 4 parallel-connected parallel UPS units UPS units 99.99947% up to 4 x M1 ** 4 parallel-connected 3. Integrated UPS units parallel units and external maintenance bypass 4. Isolated redund. 99.99970% 6.8 x M1 ** Flexible 5. Centralised 99.99968% 6.5 x M1 ** 6 parallel-connected SSC UPS units 6. Total isolation, 99.99968% 6.5 x M1 *** 6 parallel-connected single busbar UPS units 7. Total isolation, 99.99968% 6.5 x M1 *** 6 parallel-connected double busbar UPS units 8. Total isolation, 99.99968% 6.5 x M1 **** 6 parallel-connected single busbar UPS units 9. Total isolation, 99.99968% 6.5 x M1 **** 6 parallel-connected double busbar UPS units Multi-source configurations Standard diagram number 10. Isolated redundancy 11. With STS 12. STS + PDU Criteria for comparison Availability MTBF 99.99970% 7 x M1 99.99970% 7 x M1 99.99930% The highest level of availability Maintainability Upgradeability ** No limit **** **** No limit to the power rating No limit to the power rating Comment No propagation of faults + load management **** excellent *** good ** fair * poor APC by Schneider Electric 05/2009 edition ch. 2 - p. 5 Diagram no. 1. Single UPS Fig. 2.7. Double-conversion single-UPS unit. This is the basic solution for UPS installations. The double-conversion UPS unit supplies high-quality voltage, whatever the level of disturbances in the utility power. Availability of power for the load 99.99790% and an MTBF of 475 000 hours, compared to a utility MTBF of 96 hours. UPS maintenance Made easy due to the built-in bypass for supply of power to the load during servicing. Possible upgrades On site by connecting several identical UPS units in parallel. Applicable ranges MGETM GalaxyTM 3500, PW, 5000, 7000, 9000. APC by Schneider Electric 05/2009 edition ch. 2 - p. 6 Diagram no. 2. Active redundancy with two integrated parallel UPS units Fig. 2.8. Active redundancy with two integrated parallel UPS units. A simple solution where the UPS units share the load. Availability of power for the load 99.99947% and an MTBF up to four times higher than that for a single UPS. UPS maintenance During maintenance on one unit, the load remains protected by the other. Possible upgrades Several identical UPS units can be connected in parallel and equipped with an external maintenance bypass. Special characteristics The automatic-bypass function is ensured by managing the static switches. Centralised monitoring of the various modules. Can be used only with two identical units. Applicable ranges MGETM GalaxyTM 3500, PW, 5000, 7000, 9000. APC by Schneider Electric 05/2009 edition ch. 2 - p. 7 Diagram no. 3. Active redundancy with integrated parallel UPS units and external maintenance bypass Fig. 2.9. Active redundancy with integrated parallel UPS units and external maintenance bypass. An upgradeable solution where the power rating can be increased up to 4000 kVA*. Availability 99.99947% and an MTBF up to four times higher than that for a single UPS. UPS maintenance During maintenance on one unit, the load remains protected by the other units. Easy upgrades Several identical UPS units can be connected in parallel for a low cost solution with small dimensions. Special characteristics The UPS units share the load. The automatic-bypass function is ensured by managing the static switches. Centralised monitoring of the various modules. Identical modules must be used. Applicable ranges MGETM GalaxyTM 3500 PW 5000 7000 9000 Max. number of parallel-connected units 4 4 6 8 4 * Power rating for N+1 redundancy. APC by Schneider Electric 05/2009 edition ch. 2 - p. 8 Diagram no. 4. Isolated redundancy with two UPS units Fig. 2.10. Isolated redundancy with two UPS units. An extremely flexible solution that can combine heterogeneous and distant UPS units. It also offers improved backup time and is perfectly suited to the technology implemented by MGE Galaxy UPSs from APC by Schneider Electric which provide excellent withstand capacity for load step changes. Availability 99.99970% and an MTBF 6.8 times higher than that of a single UPS. UPS maintenance During maintenance on one unit, the load remains protected. Special characteristics For a single load, the two UPS units have the same power rating, but if there is a second load (possible load), the rating of the backup UPS unit must be adapted correspondingly. No control wires between the UPS units. Applicable ranges MGETM GalaxyTM 3500, PW, 5000, 7000, 9000. APC by Schneider Electric 05/2009 edition ch. 2 - p. 9 Diagram no. 5. Active redundancy with parallel units and centralised static-switch cubicle (SSC) Fig. 2.11. Active redundancy with parallel units and centralised static-switch cubicle (SSC). The solution for centralised installations up to 4 MVA*. Excellent reliability due to the independence between the units and the static-switch cubicle (SSC). Availability 99.99968% and an MTBF up to 6.5 times higher than that for a single UPS. UPS maintenance During maintenance on one unit, the load remains protected by the other units and the SSC. During maintenance on the SSC, redundancy of the UPS units is maintained. Easy upgrades Up to eight UPS units. Special characteristics The UPS units share the load. Applicable range MGETM GalaxyTM 7000, 9000. The Symmetra series is designed according to this type of diagram with hotswappable rack-mounted power modules. * Power rating for N+1 reduncancy. APC by Schneider Electric 05/2009 edition ch. 2 - p. 10 Diagram no. 6. Active redundancy with parallel UPS units and total isolation, single busbar Fig. 2.12. Active redundancy with parallel UPS units and total isolation, single busbar. A solution that can evolve with needs up to 4 MVA*. Excellent reliability and improved maintainability due to the total independence between the UPS units and the static-switch cubicle (SSC). Availability 99.99968% and an MTBF up to 6.5 times higher than that for a single UPS. UPS maintenance During maintenance on one unit, the load remains protected by the other units and the SSC. During maintenance on the SSC, redundancy of the UPS units is maintained. Easy upgrades Up to eight UPS units. Special characteristics Total isolation of the UPS units or the SSC for maintenance. The UPS units can be tested using a test load. Isolation of each UPS unit and the SSC, thus eliminating the single point of failure in the SSC. Applicable range TM MGE Galaxy TM 7000, 9000. * Power rating for N+1 redundancy. APC by Schneider Electric 05/2009 edition ch. 2 - p. 11 Diagram no. 7. Active redundancy with parallel UPS units and total isolation, double busbar Fig. 2.13. Active redundancy with parallel UPS units, double SSC and total isolation, double busbar. A solution that can evolve with needs up to 4 MVA*. Excellent reliability and improved maintainability due to the total independence between the UPS units, the static-switch cubicle (SSC) and the busbars. Availability 99.99968% and an MTBF up to 6.5 times higher than that for a single UPS. UPS maintenance During maintenance on the UPS units and one busbar, the load remains protected by the other units and the SSC, which are parallel-connected to the second busbar. During maintenance on the SSC, redundancy of the UPS units is maintained. Easy upgrades Up to eight UPS units. Special characteristics Transfer from one busbar to the other without disturbing the load. Total isolation of the UPS units or the SSC for maintenance. Isolation of each UPS unit and the SSC, thus eliminating the single point of failure in the SSC. Applicable range MGETM GalaxyTM 7000, 9000. * Power rating for N+1 redundancy. APC by Schneider Electric 05/2009 edition ch. 2 - p. 12 Diagram no. 8. Active redundancy with parallel UPS units, double SSC and total isolation, single busbar Fig. 2.14. Active redundancy with parallel UPS units, double SSC and total isolation, single busbar. An upgradeable solution offering improved maintainability due to the total redundancy of the UPS units and the static-switch cubicles (SSC). Availability 99.99968% and an MTBF up to 6.5 times higher than that for a single UPS. UPS maintenance During maintenance on the UPS units and one SSC, the load remains protected by the other units and the second SSC. During maintenance on one SSC, redundancy of the UPS units is maintained. Easy upgrades Up to eight UPS units. Special characteristics Only one SSC is active, the other is on stand-by and transfer of the UPS units from one to the other takes place without disturbing the load. During operation on the bypass, the load is split 50/50 between the two SSCs. Total isolation of each SSC for maintenance. Parallel connection of the UPS units in the output cabinet eliminates the single point of failure in an SSC. The possibility of installing the SSCs in two separate rooms increases system availability in the event of fire or other problems. Applicable range MGETM GalaxyTM 7000, 9000. APC by Schneider Electric 05/2009 edition ch. 2 - p. 13 Diagram no. 9. Active redundancy with parallel UPS units, double SSC and total isolation, double busbar Fig. 2.15. Active redundancy with parallel UPS units, double SSC and total isolation, double busbar. A solution for two evolving loads with different needs in terms of power ratings and redundancy. Availability 99.99968% and an MTBF up to 6.5 times higher than that for a single UPS. UPS maintenance During maintenance on one UPS unit and one SSC, the load remains protected by the other units and the second SSC. During maintenance on one SSC, redundancy of the UPS units is maintained. Easy upgrades Up to eight UPS units. Special characteristics During operation of only one load, only one SSC is active, the other is on stand-by and transfer of the UPS units from one to the other takes place without disturbing the load. During operation of the two different loads, both SSCs are active, each with a number of assigned UPS units. Parallel connection of the UPS units in the output cabinet eliminates the single point of failure in an SSC. The possibility of installing the SSCs in two separate rooms increases system availability in the event of fire or other problems. Applicable range MGETM GalaxyTM 7000, 9000. APC by Schneider Electric 05/2009 edition ch. 2 - p. 14 Diagram no. 10. Isolated redundancy N+1 Fig. 2.16. Isolated redundancy N+1. Solution combining heterogeneous and distant UPS units to protect a number of independent loads. Availability of power for the load Greater than 99.99970% and an MTBF up to seven times higher than that for a single UPS. UPS maintenance During maintenance on one UPS unit, the load remains protected. However, the UPS units are not totally isolated (servicing under energised conditions). Possible upgrades No limit to the power rating. Short-circuit propagation Impossible between the sources. Special characteristics Short-circuit capacity is lower than in a configuration with parallel UPS units (Isc, discrimination, crest factor, etc.). Sizing of the backup UPS must take into account the number of UPS units downstream, their power ratings and their criticality, as well as any future plans for the installation (generally speaking, the backup UPS has a parallel configuration). All the advantages of isolated redundancy (diagram no. 4). Applicable ranges MGETM GalaxyTM 3500, 5000, 7000. APC by Schneider Electric 05/2009 edition ch. 2 - p. 15 Diagram no. 11. Redundant distribution with STS Fig. 2.17. Redundant distribution with STS units. APC by Schneider Electric 05/2009 edition ch. 2 - p. 16 Diagram no. 11. Redundant distribution with STS (cont.) The best solution in terms of availability, site operation and safety. It is the only solution that deals with power distribution through to the loads. It is particularly flexible and makes for easy adaptation of redundancy to the needs of the load. Availability of power for the load Greater than 99.9999%, the highest level of availability! UPS maintenance Total distribution redundancy and servicing under no-load conditions make for maximum safety during maintenance. Easy upgrades Using single-UPS units and with no limit to the total power rating, upgrading is made easy by the capacity to partially isolate distribution subassemblies. Fault propagation Load segmenting and the technology employed in Upsilon STS units (break-beforemake source transfer with no interruption to the loads) ensures isolation of loads from disturbances caused by other, faulty loads. Easy operation Automatic or manual source transfer. Continuous monitoring of the sources (11 parameters and internal circuits). Secure transfer of desynchronised sources. Special characteristics The synchronisation module ensures perfect source synchronisation under all conditions (long outages, etc.). Selection of the load distribution for the UPS units. The UPS units can be heterogeneous and remote from the load. Applicable ranges TM TM All 3-phase ranges from APC by Schneider Electric: MGE Galaxy and TM Symmetra . APC by Schneider Electric 05/2009 edition ch. 2 - p. 17 Diagram no. 12 . Active redundancy with parallel UPS and a common battery PDU 1 PDU 2 PDU 3 Fig. 2.18. Redundant distribution with STS units and PDU. Redundancy is built into each level, including the PDUs, the Upsilon STS units, the Galaxy UPS units and the synchronisation modules. Same advantages as diagram no. 11, plus: Capacity to enhance the reliability of a particular point in the installation. Four different supply channels to dual-attach servers. Applicable ranges All 3-phase ranges from APC by Schneider Electric: MGETM GalaxyTM and TM Symmetra . APC by Schneider Electric 05/2009 edition ch. 2 - p. 18 Chapter 3. Elimination of harmonics in installations Contents Harmonics........................................................................3-2 Definition, origin and types of harmonics..............................................3-2 Characteristic harmonic values ............................................................3-5 Effects of harmonics.............................................................................3-7 Elimination of harmonics ...............................................3-11 Strategies against harmonics ...............................................................3-11 Living with harmonics ...........................................................................3-11 APC by Schneider Electric solutions to eliminate harmonics ...............3-12 MGETM SineWaveTM Active harmonic conditioners........................................3-14 MGETM SineWaveTM active harmonic conditioner ranges .....................3-14 Procedure for implementing active conditioning ...................................3-20 APC by Schneider Electric 05/2009 edition ch 3 p. 1 Harmonics Definition, origin and types of harmonics Harmonics Harmonics are sinusoidal currents or voltages with a frequency that is a whole multiple (k) of the frequency of the distribution system, called the fundamental frequency (50 or 60 Hz). When combined with the sinusoidal fundamental current or voltage respectively, harmonics distort the current or voltage waveform (see fig. 3.1). Harmonics are generally identified as Hk, where k is the harmonic order. IHk or UHk indicate the type of harmonic (current or voltage). IH1 or UH1 designates the sinusoidal current or voltage at 50 or 60 Hz that exists when there are no harmonics (the fundamental current or voltage). H1 (50 Hz) H3 (150 Hz) H1 + H3 Fig. 3.1. Distortion of H1 (the fundamental) by H3 (third-order harmonic). Non-linear loads are the cause Equipment implementing power electronics is the main cause of harmonics. To supply the electronics with DC power, the equipment has a switch-mode power supply with a rectifier at the input that draws harmonic currents. Examples are computers, variable-speed drives, etc. Other loads distort the current due to their operating principle and also cause harmonics. Examples are fluorescent lamps, discharge lamps, welding machines and devices with a magnetic core that can be saturated. All the loads that distort the normal sinusoidal current cause harmonics and are called non-linear loads. PC. Variable-speed drive. Fluorescent lamp. Fig. 3.2. Examples of non-linear loads that cause harmonics. Linear and non-linear loads Utility power supplies 50/60 Hz sinusoidal voltage to loads. The current waveform supplied by the source in response to the needs of the load depends on the type of load. Linear loads The current drawn is sinusoidal with the same frequency as the voltage. The current may be displaced (angle ) with respect to the voltage. Ohm's law defines a linear relation between the voltage and the current (U = ZI) with a constant coefficient, the load impedance. The relation between the current and the voltage is linear. Examples are standard light bulbs, heating units, resistive loads, motors, transformers. This type of load does not contain any active electronic components, only resistors (R), inductors (L) and capacitors (C). APC by Schneider Electric 05/2009 edition ch 3 p. 2 Harmonics (cont.) Non-linear loads The current drawn by the load is periodic, but not sinusoidal. The current waveform is distorted by the harmonic currents. Ohm's law defining the relation between the total voltage and current (1) is no longer valid because the impedance of the load varies over one period (see fig. 3.3). The relation between the current and the voltage is not linear. The current drawn by the load is in fact the combination of: - a sinusoidal current called the fundamental, at the 50 or 60 Hz frequency, - harmonics, which are sinusoidal currents with an amplitude less than that of the fundamental, but a frequency that is a multiple of the fundamental and which defines the harmonic order (e.g. the third order harmonic has a frequency 3 x 50 Hz (or 60 Hz)). (1) Ohm's law applies to each voltage and current of the same harmonic order, Uk = Zk Ik, where Zk is the load impedance for the given order, but is no longer valid for the total voltage and current. Linear loads, non-linear loads, see Ch. 1 p. 11 "UPS power quality". An example is RCD loads (Resistance, Capacitor, Diode) that are found in a majority of power supplies used for electronic devices. ● The capacitor C, under steady-state conditions, charges only when the instantaneous line voltage is greater than the voltage across its terminals. ● From that point on, the load impedance is low (diode turned on). Before, the impedance was high (diode turned off). ● The impedance of a non-linear load therefore varies according to the voltage across its terminals. ● The impedance is not constant and the voltage and current are no longer sinusoidal. ● The form of the current is more complex and can be represented, using the Fourier theorem, by adding: - a current with the same frequency f as the voltage, called the fundamental, - other currents with frequencies kf (k is a whole number > 1) called harmonics. ● The figure provides a general idea of the load current showing only two harmonic orders, IH3 and IH5. Fig. 3.3. Voltage and current for non-linear loads Types of harmonics and specific aspects of zero-sequence harmonics Types of harmonics Non-linear loads cause three types of harmonic currents, all in odd orders (because the sinusoidal is an "odd" function). Harmonics H7 - H13 - …. : positive sequence. Harmonics H5 - H11 - …. : negative sequence. Harmonics H3 - H9 - …. : zero sequence. Specific aspects of zero-sequence harmonics (H3 and multiples) Zero-sequence harmonic currents (H3 and odd multiples, written 3(2k+1) where k is an integer) in three-phase systems add up in the neutral conductor. This is because their order 3(2k+1) is a multiple of the number of phases (3), which means they coincide with the displacement (one third of a period) of the phase currents. Figure 3.4 illustrated this phenomenon over one period. The currents of the three phases are displaced one third of a period (T/3), i.e. the respective IH3 harmonics are in phase and the instantaneous values add up. Consequently: When there are no harmonics, the current in the neutral is equal to zero: IN = I1+I2+I3 = 0 When there are harmonics, the current in the neutral is equal to: I1 + I2 + I3 = 3 IH3 . It is therefore necessary to pay particular attention to this type of harmonics in installations with a distributed neutral (commercial and infrastructure applications). APC by Schneider Electric 05/2009 edition ch 3 p. 3 Harmonics (cont.) Fig. 3.4. The third-order harmonics and their multiples add up in the neutral. Fig. 3.5. When there are H3 harmonics and their odd multiples, the current in the neutral is no longer equal to zero, it is the sum of the zero-sequence harmonics. APC by Schneider Electric 05/2009 edition ch 3 p. 4 Harmonics (cont.) Characteristic harmonic values See WP 17 The harmonic analysis of a non-linear current consists in determining: the harmonic orders present in the current, the relative importance of each harmonic order. Below are a few characteristic harmonic values and fundamental relations used in harmonic analysis. Further information on harmonics, see Ch. 5 and the explanations in White Paper no. 17 "Understanding Power Factor, Crest Factor and Surge Factor". Rms value of harmonics It is possible to measure the rms value of each harmonic order because the various harmonic currents are sinusoidal, but with different frequencies that are multiples of the fundamental frequency. IH1 is the fundamental component (50 or 60 Hz). IHk is the harmonic component where k is the harmonic order (k times 50 or 60 Hz). Harmonic analysis is used to determine the values. Total rms current Irms IH12 IH22 IH3 2 ... IHk 2 ... Individual harmonics Each harmonic is expressed as a percentage, i.e. the ratio of its rms value to the rms value of the fundamental. This ratio is the level of the individual harmonic. IH Hk% = distortion of harmonic k = 100 k IH1 Voltage and current harmonic distortion Non-linear loads cause both current and voltage harmonics. This is because for each load current harmonic, there is a supply voltage harmonic with the same frequency. As a result, the voltage is also distorted by harmonics. The distortion of a sine wave is presented as a percentage: rms value of all harmonics THD* % = total distortion = 100 rms value of fundamental * Total Harmonic Distortion. The following values are defined: TDHU % for the voltage, based on the voltage harmonics, TDHI % for the current, based on the current harmonics. The THDI (or the THDU using the UHk values) is measured using the equation: THDI % 100 IH22 IH3 2 IH4 2 ... Hk 2 ... IH1 Crest factor The crest factor (Fc), used to characterise the form of the signal (current or voltage), is the ratio between the peak value and the rms value. Fc peak value rms value Below are typical values for different loads: linear load: Fc = 2 = 1.414 main frame: Fc = 2 to 2.5 microcomputers: Fc = 2 to 3. APC by Schneider Electric 05/2009 edition ch 3 p. 5 Harmonics (cont.) Spectrum of the harmonic current Defining the spectrum of a harmonic current consists in determining the current waveform and the individual harmonics, as well as certain values such as the THDI and Fc. Individual harmonics H5 = 33 % H7 = 2.7 % H11 = 7.3% H13 = 1.6 % H17 = 2.6 % H19 = 1.1 % H23 = 1.5 % H25 = 1.3 % THDI = 35% Fc = 1.45 Input current of a three-phase rectifier. Harmonic spectrum and corresponding THDI. Fig. 3.6. Harmonic spectrum of the current drawn by a non-linear load. Power factor Power factor The power factor is the ratio between the active power (kW) and the apparent power S (kVA) across the terminals of a given non-linear load. P (kW ) S (kVA ) It is not the phase displacement between the voltage and the current, because they are no longer sinusoidal. Displacement between the fundamental current and voltage The phase displacement 1 between the fundamental current and voltage, both sinusoidal, can be defined as: P1 (kW ) cos 1 S1 (kVA ) where P1 and S1 are the active and apparent power, respectively, of the fundamental. Distortion factor The distortion factor is defined as: THDI2 (as defined by IEC 60146). cos 1 When there are no harmonics, this factor is equal to 1 and the power factor is simply the cos . Power Linear load Across the terminals of a balanced, three-phase linear load, supplied with a phaseto-phase voltage U and a current I, where the displacement between U and I is , the power values are: P apparent = S = UI, in kVA, P active = S cos , in kW, P reactive = Q = S sin , in kVAr, S P2 Q2 Non-linear load Across the terminals of a non-linear load, the equation for P is much more complex because U and I contain harmonics. It can however be expressed simply as: P = S ( = power factor) For the fundamentals U1 and I1, displaced by 1: P apparent fundamental = S1 U1 I1 3 P active fundamental = P1 = S1 cos 1 P reactive fundamental Q1 = S1 sin 1 S APC by Schneider Electric P12 Q12 D2 where D is the distortion power, due to the harmonics. 05/2009 edition ch 3 p. 6 Harmonics (cont.) Effects of harmonics Loss of apparent power In electrical devices, harmonics Figure 3.7 shows that the product of a voltage at the fundamental frequency without harmonics multiplied by a third-harmonic current is zero at the end of one period. This is true whatever the phase and order of the harmonic. produce neither active nor reactive power, only losses through the Joule 2 effect (ri ). See WP 26 This is expressed by the relation S P12 Q12 D2 A part of the apparent power is consumed by the harmonics, to no effect. In rotating machines, the resulting motor torque is equal to zero and only a parasitic pulsating torque exists, creating vibrations. The only active power present during a voltage drop is the heating produced by the harmonic current (Ihk) in a conductor with a resistance r (r IHk2). See White Paper no. 26 “Hazards of Harmonics and Neutral Overloads” for further information. Fig. 3.7. U x I products for fundamentals (top) and for fundamentals with harmonics (bottom). Temperature rise due to harmonic Temperature rise in cables currents adds to the temperature rise due to the fundamental current. Temperature rise in cables is expressed as: Losses = r IHn 2 n 1 APC by Schneider Electric 05/2009 edition ch 3 p. 7 Harmonics (cont.) The neutral must be oversized to take into account the third-order harmonic currents and their multiples. Current in the neutral All third-order harmonic currents and their odd multiples add up in the neutral (see fig. 3.8). The current in the neutral can reach 1.7 times that in the phases. Consequences Significant losses in the neutral r Ineutral2 = temperature rise in the neutral. Fig. 3.8. The third-order harmonics and their multiples add up in the neutral. Self-polluting loads Voltage distortion mirrors that of the current and increases in step with the sum of the impedances upstream of the non-linear load. Current distortion THDI, caused by the load, results in voltage distortion THDU caused by the harmonic currents flowing through the various impedances from the source on down. Figure 3.9 shows the various forms of distortion throughout a common electrical installation. Fig. 3.9. Effects of harmonics throughout the installation. APC by Schneider Electric 05/2009 edition ch 3 p. 8 Harmonics (cont.) Risk of capacitor breakdown In conclusion, the higher the content of high-order components in the voltage, the worse the situation for the capacitor. It is often necessary to use reinforced capacitors. The value of a current in a capacitor is equal to: .I = U C For a harmonic current of order k, the angular frequency is equal to = 2 k f, and the current is equal to: .I = 2 k f U C where f = the fundamental frequency and k = the harmonic order. It follows that the value of the current increases with k. What is more, for a harmonic frequency, there can also be resonance (1) of the capacitor (capacitance C) with the equivalent inductance (L) of the source (transformer, essentially inductive) in parallel with that of the other supplied loads. This resonant circuit (see fig. 3.10) significantly amplifies the harmonic current of the corresponding order, thus worsening the situation for the capacitor. (1) This is the case if, for a harmonic order k, with a frequency fk = k x 50 (or 60) Hz, LCk where = 2 π fk. 2 ˜ 1, IH Source impedance (transformer) in parallel with that of other loads supplied harmonic currents L resonant LC circuit C All non-linear loads Fig. 3.10. Effects of harmonics with capacitors, risk of resonance. Consequences Risk of capacitor breakdown. Risk of resonance due to the presence of the inductors. Certain limitations must be respected: U max = 1.1 Un I max = 1.3 In THDU max = 8% Selection of capacitor type, depending on the situation, i.e. standard, class h (reinforced isolation), with harmonic inductors. Derating of transformers Generally speaking, harmonics result in source derating that is inversely proportional to the load power factor, i.e. the lower the power factor, the more the source must be derated. A number of effects are combined: due to the skin effect, the resistance of a transformer winding increases with the order of the harmonics, losses due to hysteresis are proportional to the frequency, losses due to Foucault currents are proportional to the square of the frequency. Consequences In compliance with standard NFC 52-114, transformers must be derated by applying a coefficient k to their rated power, such that: k 1 n H n 2 1,6 n 1 0,1 n2 This is an empirical equation. Other national standards recommend derating using a similar k factor that depends on the country (e.g. BS 7821 Part 4, IEE 1100-1992). Example A 1000 kVA transformer supplies a six-pulse rectifier bridge drawing the following harmonics: H5 = 25%, H7 = 14%, H11 = 9%, H13 = 8%. The derating coefficient is k = 0.91. The apparent power of the transformer is therefore 910 kVA. APC by Schneider Electric 05/2009 edition ch 3 p. 9 Harmonics (cont.) Risk of disturbing generators Practically speaking, the THDI of the current in the generator must not exceed 20%. Above, derating is necessary. Similar to transformers, generators suffer greater losses due to hysteresis and Foucault currents. The subtransient reactance X"d increases as a function of the frequency. The "harmonic" rotating field sweeps the rotor at a frequency other than the synchronism frequency (50 or 60 Hz). Consequences Creation of parasitic torque resulting in lower efficiency of the mechanical to electrical conversion. Additional losses in the inductor windings and the rotor damper. Presence of vibration and abnormal noise. Losses in asynchronous motors Harmonics produce the following effects in asynchronous motors: increases in Joule and iron losses (stator losses), pulsating torque (rotor losses with a drop in mechanical efficiency). The THDU must be less than 10% to limit these phenomena. Effects on other equipment Harmonics can disturb operation of the following equipment as well: non-rms trip units, resulting in nuisance tripping of circuit breakers, automatic telephone exchanges, alarms, sensitive electronic equipment, remote-control systems. Effect on recent UPS systems Modern UPS systems have high chopping frequencies (PWM) and very low output impedance (equivalent to a transformer five times more powerful). When confronted with non-linear loads, these UPSs offer: limited losses, current-limiting operation, very low voltage distortion (THDU < 3%). UPSs are an excellent means to supply non-linear loads. Conclusion Harmonics may have damaging effects on electrical installations and on the quality of operation. That is why international standards stipulate increasingly precise harmoniccompatibility levels for equipment and set limits for the harmonic content on public distribution systems. Standards on harmonics, see Ch. 5 p. 28 "UPS standards". On the following pages are a presentation of the various strategies concerning harmonics and the usefulness of MGETM SineWaveTM active harmonic conditioners. APC by Schneider Electric 05/2009 edition ch 3 p. 10 Elimination of harmonics Strategies against harmonics There are two strategies: accept and live with harmonics, which essentially means it is necessary to oversize equipment to take the effects of harmonics into account, eliminate the harmonics, in part or in whole, using filters or active harmonic conditioners. Living with harmonics Oversizing of equipment See WP 38 Given that the negative effects of harmonic currents increase with the cumulative impedance of cables and sources, the obvious solution is to limit the total impedance in order to reduce both voltage distortion and temperature rise. Figure 3.11 shows the results when cable cross-sections and the power rating of the source are doubled. Given that the THDU depends primarily on the inductive component and thus on the length of the cables, it is clear that this solution is not very effective and results simply in limiting temperature rise. Figure 3.12 shows that for the strongest harmonic currents (H3 to H7), the L/R ratio is equal to 1 for cables with a cross-section of 36 mm². Consequently, above 36 mm², it is necessary to reduce the impedance by using multicore cable to create parallel impedances. For Data Centers, see “Harmonic Currents in the Data Center: A Case Study”. Fig. 3.11. Increased cable cross-sections to limit distortion and losses. Fig. 3.12. Influence of cable cross-section on L/R. APC by Schneider Electric 05/2009 edition ch. 3 - p. 11 Elimination of harmonics (cont.) APC by Schneider Electric solutions to eliminate harmonics There are different types of solutions to eliminate harmonics. Filters, see Ch.1 p. 27 “ Selection of a filter” . Passive filters LC passive filters are tuned to the frequency requiring elimination or attenuate a band of frequencies. Harmonic recombination systems (double bridge, phase shifting) can also be grouped in this category. On request, APC by Schneider Electric can integrate this type of filter in its solutions. Passive filters have two major disadvantages: elimination of harmonics is effective only for a specific installation, i.e. the addition or removal of loads can disrupt the filtering system, it is often difficult to implement them in an existing installation. Active filters / active harmonic conditioners TM TM Active filters, also called active harmonic conditioners, such as MGE SineWave , cancel harmonics by injecting exactly equal harmonic currents where they arise. This type of filter reacts in real time (i.e. actively) to the existing harmonics in order to eliminate them. More effective and flexible than passive filters, they avoid their disadvantages and, in comparison, constitute a solution that: offers greater performance (total elimination of all harmonics is possible, up to the 50th order), is flexible, adaptable (action can be configured) and reusable. Table summing up the possible strategies against harmonics Strategy Advantages Disadvantages APC by Schneider Electric solutions Live with harmonics Reduction in supply Increase the ratings of sources and/or the cross- THDU by reducing the source impedance. sections of cables Reduction in Joule losses. Difficult in existing solutions. Costly solution limited to reducing the resistive component for small crosssections (the inductance remains constant). Requires parallel cables for large cross-sections. Does not avoid disturbances upstream of the installation. Does not comply with standards. Special supply for nonLimits disturbances to Same as above. linear loads. neighbouring loads through decoupling. Partially eliminate harmonics Simple solution. Tuned passive filters. Only for one or two harmonic orders. Wide-band filters are not very effective. Possibility of resonance. Costly design work is required. Inductors upstream of the Reduction in harmonic Increase in THDU across the terminals of the load. currents. Limits the non-linear loads. effects of transient overvoltages. Elimination of only certain harmonic orders. NonSpecial transformers. standard construction. Completely eliminate harmonics Active harmonic Simple and flexible Total elimination of all harmonics is possible (up to the th conditioners. solution. 25 order), adaptable (action configured) and reusable system. APC by Schneider Electric 05/2009 edition Range of passive filters Including double-bridge and phaseshifting solutions TM TM MGE SineWave active conditioners ch. 3 - p. 12 MGETM SineWaveTM active harmonic conditioners MGETM SineWaveTM active harmonic conditioners MGETM SineWaveTM characteristics MGETM SineWaveTM active harmonic conditioners MGETM SineWaveTM active harmonic conditioners constitute a more general approach to the problem of harmonics. These active filters are not only for a UPS unit, but are designed to eliminate harmonics throughout the installation. MGETM SineWaveTM is particularly well suited to medium-power industrial and infrastructure applications, offering conditioning currents from 20 to 480 A in threephase systems with a neutral. These solutions are presented in the following section. The table below sums up the main characteristics. Range MGE TM SineWave TM Power level 50/60 Hz systems Main characteristics Applications 20 to 480 A 380 to 415 V 3 Ph+N and 3 Ph ● Filtering up to H25 ● Digital active Filtering of mediumpower commercial, infrastructure and industrial systems, 3Ph+N and 3 Ph, single-phase loads conditioning with: - analysis and conditioning of individual orders - response time 40 ms for load fluctuations Advantages of MGETM SineWaveTM active harmonic conditioning Wide-band solution from H2 to H25 with individual conditioning of each phase. It is possible to select individual harmonic orders for conditioning. No risk of overloads, conditioning limits to the maximum power rating, even if the load power exceeds the rating. Automatically adapts to all types of loads, single-phase and three-phase. Compatible with all system earthing arrangements. Power factor correction. Economic, when harmonics are cut in half, losses are reduced by four. Can be reused in other installations. Upgradeable with parallel-connected units. Very compact. Simple installation, with current transformers upstream or downstream. Operating principle The source supplies exclusively the fundamental component (IF) of the load current. The active conditioner measures in real time the harmonics (IH) drawn by the load and supplies them. Upstream of point A, where the conditioner is connected, the fundamental current IF is not altered, downstream the load draws the non-linear current IF + IH. IF IF + IH A Source Injection of compensation current Active harmonic conditioner Fig. 3.13. Harmonic conditioning by MGE APC by Schneider Electric 05/2009 edition Non-linear load IH TM Measurement of load harmonics TM SineWave . ch. 3 - p. 13 MGETM SineWaveTM active harmonic conditioners (cont.) Operating modes Digital mode, conditioning of individual orders The basic operating mode of MGETM SineWaveTM is digital, with a current sensor, analogue/digital conversion of the current measurements and real-time calculation of the harmonic spectrum. This information is supplied to the inverter for compensation of the individual harmonic orders. The response time to load fluctuations is 40 ms (two cycles). Operating diagram The power required for conditioning is drawn on the three-phase distribution system and stored in the inductor L and the capacitors charged to +Vm and -Vm respectively (see fig. 3.14). Depending on the sign of the harmonic current required, the pulse width of one capacitor or the other is modulated. This means the same connection to the supply system can be used to draw power and inject the harmonics. The power sent to the load depends on: The harmonic values measured, User requirements, set during system configuration: harmonic orders to be eliminated and power-factor correction (yes or no). The current transformer, combined with an analogue/digital converter, determines the spectrum (fundamental and harmonics) of the current supplying the load. Depending on these values and the selecting program, a processor prepares the commands for the inverter, for execution one phase after the measurements. Power factor correction is obtained by generating a fundamental current +90° out of phase with the voltage TM Fig. 3.14. Operation of MGE SineWaveTM. Options On 3Ph or 3 ph+N systems, the user can decide to condition: All or only certain harmonics up to H25. The power factor MGETM SineWaveTM is always supplied with three-phase power, but it can condition single-phase loads, i.e. 3k zero-sequence harmonics. APC by Schneider Electric 05/2009 edition ch. 3 - p. 14 MGETM SineWaveTM active harmonic conditioners (cont.) Installation modes Parallel mode Up to four MGETM SineWaveTM active harmonic conditioners can be connected in parallel at the same point of installation. This the means to increase harmonicconditioning capacity and/or system availability. For parallel installations, a single set of sensors is required on the conditioned circuit and a wire link is used to send the load-current measurements to the various conditioners. If one conditioner shuts down, the remaining conditioners continue to condition the harmonics, within the limits of their rated conditioning capacity. Fig. 3.15. Parallel operation of three MGE TM SineWave TM active harmonic conditioners. Cascade or in-series mode "Cascade" or "in-series" operation is possible, but simply requires special settings to avoid any interaction between the different conditioners. The downstream conditioner generally conditions a high-power load. The upstream device conditions other low-power outgoing circuits and, where applicable, any residual harmonics not conditioned by the first conditioner. Fig. 3.16. MGE TM SineWave TM active harmonic conditioners in cascade mode. Multi-circuit mode In this mode, a single conditioner can condition up to three outgoing circuits. A set of sensors is required for each circuit conditioned and all are connected to MGETM SineWaveTM . This configuration is very useful when the harmonics are concentrated on a small number of circuits. Fig. 3.17. One MGE APC by Schneider Electric TM SineWave 05/2009 edition TM active conditioner for several circuits. ch. 3 - p. 15 MGETM SineWaveTM active harmonic conditioners (cont.) Position in the installation Total (or centralised) conditioning The active harmonic conditioner is connected just downstream of the sources, generally at the main low-voltage switchboard (MLVS) level. Partial conditioning The active harmonic conditioner is connected at the main or secondary switchboard level and conditions a set of loads. Local conditioning The active harmonic conditioner is connected directly to the terminals of each load Fig. 3.18. Three possible MGE requirements. TM SineWave TM installation points, depending on user Comparison of installation possibilities Type of conditioning Total (MLVS level) Advantages Economical. Relieves generators (transformers, generators). Partial (secondary-switchboard level) Avoids oversizing the cables between the main and secondary switchboards. Recombination of certain harmonics may make it possible to reduce conditioner rating. Eliminates harmonics where they Costly when a number of occur. conditioners are required. Reduces losses in all cables, up to the source. Local (load level) APC by Schneider Electric Disadvantages Harmonics remain in the downstream part of the installation. Cables must be oversized. Harmonics remain between the secondary switchboard and the non-linear load. Outgoing cable to the load must be oversized. 05/2009 edition Applications Compliance with utility requirements. Avoid injecting harmonics upstream of the installation. Large buildings. Conditioning regularly spaced on each floor or set of floors. Several circuits supplying non-linear loads. For installations where non-linear loads are few in number and high-powered with respect to the other loads. Example, large variable-speed drives, high-power UPSs. Examples: server bays, lighting, highpower UPSs, fluorescent lighting systems. ch. 3 - p. 16 MGETM SineWaveTM active harmonic conditioners (cont.) Practically speaking Total conditioning does not pose any calculation problems. Partial conditioning requires a few precautions. For all non-compensated RCD loads (high-power variable-speed drives without inductors for variable-torque applications), local conditioning can guarantee only a THDU not exceeding certain limits to ensure proper load operation. Position of current transformers upstream or downstream In most of the above installation modes, two different types of current-transformer (CT) installation can be used with MGETM SineWaveTM. CT upstream of the load This is the most common situation. IH IF IF + IH active harmonic conditioner CT to measure load harmonics non-linear load Fig. 3.19. Installation with one CT upstream of the load. Installation with one CT upstream of the MGETM SineWaveTM and one CT on the switchboard incomer This configuration simplifies matters when it is difficult to install a CT on the line just upstream of the load. The two CTs must have compatible and complementary characteristics. The difference between the measured currents determines the necessary compensation current. CT1 to measure source current IH IF CT2 to measure conditioner current IF + IH information on current to be reinjected (différence CT1 - CT2) active harmonic conditioner non-linear load Fig. 3.20. Installation with two CTs, one on the switchboard incomer and the other upstream of the conditioner. APC by Schneider Electric 05/2009 edition ch. 3 - p. 17 MGETM SineWaveTM active harmonic conditioners (cont.) Advantages of MGETM SineWaveTM Elimination of the conditioned harmonic currents For the selected harmonics, MGETM SineWaveTM is designed to provide a path for the harmonic currents with virtually zero impedance with respect to that of the source. This eliminates their flow upstream towards the source. TM TM Figure 3.21 shows MGE SineWave between two line sections ZL1 and ZL2, supplying a standard RCD load that can be either single or three-phase (switch-mode power supply or variable-speed drive). The harmonic currents IHn that previously flowed through impedances Zs and ZL1 upstream of the MGETM SineWaveTM point of installation, are eliminated. The source now supplies exclusively the fundamental current If. It is the MGETM SineWaveTM that supplies the harmonic currents IHn to the load, by continuously measuring the harmonics drawn by the load. TM Fig. 3.21. MGE SineWaveTM modifies the current upstream of its point of installation. Reduction in THDU at the point of installation Upstream of MGETM SineWaveTM, the selected harmonic currents IHn (all or only some of the harmonics up to the 25th) are eliminated. Total harmonic distortion upstream of the point of installation is calculated as (see Ch. 4 p. 49): UH n THDU % 100 2 n2 UH1 where UHn is the voltage drop corresponding to harmonic IHn. Elimination of the harmonic current for a given order eliminates the harmonic voltage for the same order (1). The result is a major reduction in the THDU, by selecting the most significant harmonics. Given that above the 25th order, individual harmonics are negligible, the THDU is practically equal to zero and distortion is totally eliminated if it is decided to condition all harmonics up to the 25th. (1) In that UHn and IHn are sinusoidal components at frequency nf (where f is the frequency of the fundamental), they are related by the Ohm law, taking into account the value of the concerned impedances (Zs and ZL1) with an angular frequency n. Therefore: UHn = (Zs(n) + ZL1(n)) IHn. For all the conditioned harmonics, IHn = 0 and consequently, UHn = 0. APC by Schneider Electric 05/2009 edition ch. 3 - p. 18 MGETM SineWaveTM active harmonic conditioners (cont.) Procedure for implementing active conditioning Conclusion on active conditioning Precise conditioning calculations require: precise and in-depth knowledge on the installation (sources, lines and installation method), precise knowledge on the loads (harmonic and displacement curves depending on the source impedance), special calculation tools, analysis and simulation. New installations The standard rules governing electrical installations remain valid, but an evaluation of the voltage distortion (THDU) is required where harmonic currents flow. This evaluation is very complex and requires special calculation software as well as in-depth knowledge of the non-linear loads, in particular the harmonic distribution as a function of the upstream impedance. APC by Schneider Electric has the simulation tools required for theses calculations. Existing installations For existing installations, a precise evaluation of the site is the indispensable prerequisite to any corrective action. The mathematical relationship between current and voltage distortion is complex and depends on the various components of the installation. Control over harmonic phenomena requires know-how and experience, as well as specialised tools and software (spectrum analyser, calculation software for distortion in cables, simulation software, etc.). However, even if each solution is specific to a given site, proper professional techniques and rigorous methods ensure maximum probability that the installation will operate correctly. Methodology APC by Schneider Electric has mastered the entire harmonic-elimination process and proposes a three-step approach: 1. site audit, 2. determination of the most suitable solution, 3. system installation and checks. 1. Site audit Installation diagram Before initiating a series of measurements, we suggest you draft a simplified diagram of the installation, indicating the following. types of equipment - generators: type, power rating, voltage, Usc, X"d (engine generator set). - isolation transformers: voltage, power rating, type, Usc, coupling. - distribution: type of cables, length, cross-section, installation method. - loads: power rating, type. - system earthing arrangements at the various points in the installation. operating modes - on utility power. - on engine generator sets (standby power or cogeneration). - on UPSs. downgraded operating modes - without redundancy. - on engine generator set power. This diagram should enable you to locate the different measurement points and identify critical operating phases (for evaluation by simulation or calculation). APC by Schneider Electric 05/2009 edition ch. 3 - p. 19 MGETM SineWaveTM active harmonic conditioners (cont.) Measurements Following the previous indispensable step, the measurement phase can begin, starting preferably at the source and working downstream toward the loads drawing the harmonics, in order to limit the number of measurements. The quality of measurements is more important than their quantity and makes the next step easier. Preliminary installation study This first step ends with a preliminary study of the installation: point(s) of installation of the conditioner(s), installation conditions for the protection circuit breakers, installation of sensors (energised conditions or not), possibility of shutting down the load, available space, evacuation of losses (ventilation, air-conditioning, etc.), environmental constraints (noise, EMC, etc.). 2. Determination of the most suitable solution The previous elements are used to determine the optimum solution through: analysis of the measurement results, simulation of different solutions for the problem encountered, determination of the most suitable solution, drafting of a summary report with the proposed solutions. 3. System installation and checks This last step includes: implementation of the selected solutions, checks on performance levels with respect to the guaranteed results, drafting of a system start-up report. APC by Schneider Electric 05/2009 edition ch. 3 - p. 20 Chapter 4. APC by Schneider Electric ranges Contents MGETM GalaxyTM 3500 UPSs ...........................................4-3 Presentation .........................................................................................4-3 Main features........................................................................................4-4 Installation ............................................................................................4-7 Parallel connection ...............................................................................4-7 Equipment and diagrams .....................................................................4-8 Characteristics......................................................................................4-9 MGETM GalaxyTM 5000 UPSs ...........................................4-12 Presentation .........................................................................................4-12 Main features........................................................................................4-13 Installation ............................................................................................4-17 Parallel connection ...............................................................................4-18 Equipment and diagrams .....................................................................4-19 Characteristics......................................................................................4-20 MGETM GalaxyTM PW UPSs .............................................4-24 Presentation .........................................................................................4-24 Main features........................................................................................4-24 Installation ............................................................................................4-26 Parallel connection ...............................................................................4-27 Equipment and diagrams .....................................................................4-28 Characteristics......................................................................................4-29 MGETM GalaxyTM 7000 UPSs ...........................................4-32 Presentation .........................................................................................4-32 Main features........................................................................................4-34 Installation ............................................................................................4-38 Parallel connection ...............................................................................4-39 Equipment and diagrams .....................................................................4-43 Characteristics......................................................................................4-44 MGETM GalaxyTM 9000 UPSs ...........................................4-48 Presentation .........................................................................................4-48 Main features........................................................................................4-49 Installation ............................................................................................4-52 Parallel connection ...............................................................................4-52 Equipment and diagrams .....................................................................4-55 Characteristics......................................................................................4-57 SymmetraTM PX 48 and PX 160 UPSs.............................4-60 Presentation .........................................................................................4-60 Main features........................................................................................4-61 Equipment and diagrams .....................................................................4-64 Characteristics......................................................................................4-65 SymmetraTM PX 250/500 UPSs .......................................4-68 Presentation .........................................................................................4-68 Main features........................................................................................4-69 Equipment and diagrams .....................................................................4-71 Characteristics......................................................................................4-72 SymmetraTM MW ..............................................................4-75 Presentation .........................................................................................4-75 Main features........................................................................................4-76 Equipment and diagrams .....................................................................4-78 Characteristics......................................................................................4-79 MGETM SinewaveTM active harmonic conditioners........4-82 Presentation .........................................................................................4-82 Main features........................................................................................4-83 Equipment and diagrams .....................................................................4-84 Characteristics......................................................................................4-85 MGETM Upsilon STSTM static transfer switches ............4-86 Presentation .........................................................................................4-86 Main features........................................................................................4-87 Equipment and diagrams .....................................................................4-90 Characteristics......................................................................................4-91 APC by Schneider Electric 05/2009 edition ch. 4 - p. 1 Chapter 4. APC by Schneider Electric ranges (cont.) Source synchronisation module....................................4-92 Presentation .........................................................................................4-92 Main features........................................................................................4-92 Equipment and diagrams .....................................................................4-93 Characteristics......................................................................................4-93 APC by Schneider Electric 05/2009 edition ch. 4 - p. 2 MGETM GalaxyTM 3500 UPS Presentation Performance power protection for critical applications ranging from standard electrical rooms to demanding industrial environments MGETM GalaxyTM 3500 ● 5 power ratings: Narrow tower, 325 mm wide (10, 15, 20 kVA) Fig 4.1. MGE TM Wide tower, 523 mm wide (10 to 40 kVA) TM Galaxy 10 - 15 - 20 - 30 - 40 kVA ● 2 versions: - 3-ph input and output: 10 to 40 kVA - 3-ph input - 1-ph output: 15 to 40 kVA ● Two widths, 352 mm and 523 mm for optimum footprints ● Parallel connection of up to 4 units, i.e. 4 x 40 = 160 kVA ● Double-conversion (VFI) design ● IGBT-based PFC rectifier, THDI < 5%, FP > 0.98 starting at 50% load ● Static switch and manual bypass ● Backup times from 6 min. to 8 hours depending on power rating ● Built-in modular hot-swappable batteries: (up to 4 modules of 4 batteries each) ● Highest efficiency in its category, up to 96% ● Cold-start function without AC power, on battery power ● Backfeed protection ● Designed for severe environments: - IP 51 - 2 mm steel front panel - easy-to-replace air filters 3500 range. Applications MGETM GalaxyTM 3500 is a high-performance, general-purpose UPS that can be used anywhere from standard technical rooms to demanding industrial environments. The range offers performance power protection for critical applications. ● IT and telecommunications systems. ● Infrastructure and transportation: hospitals, airports, tunnels, traffic control systems and safety infrastructure. ● Commercial and public buildings: malls, shopping centers, hypermarkets, hotels, convention centers. ● Manufacturing equipment: machine control, process control, packaging lines, laboratory equipment. ● Automation control: PLCs, industrial PCs, I/O controllers, SCADA systems. MGETM GalaxyTM 3500 is the ideal solution in its power range due to fast installation and start-up, high efficiency, redundancy, easy maintenance and heavy-duty design. Fig. 4.2. General applications in infrastructure, commercial buildings and manufacturing. Colour ● RAL 9023 grey. APC by Schneider Electric 05/2009 edition ch. 4 - p.3 MGETM GalaxyTM 3500 UPS (cont.) Main features High-performance features to meet the challenges facing building technical managers Thanks to its high level of performance, modular industrial design, heavy-duty construction and upgradeability, MGETM GalaxyTM 3500 meets the challenges facing most technical managers in commercial or industrial buildings. ● Disturbed networks. The double-conversion "on-line" technology totally protects the load and a long backup time avoids problems if a genset is not available. ● Budget limits. The small footprint saves on floor space and the optimized design reduces the total cost of ownership. ● No qualified personnel. The ease of use avoids the need for qualified personnel. Figure 4.3 sums up the key features of Galaxy 3500. p Double-conversion "on-line" topology Total load protection with no-break transfer to battery power and excellent regulation p Hot scalable backup time Modular batteries can be hot swapped p Best-in-class efficiency Up to 96% for reduced cost of ownership p Parallel connection of up to 4 units For capacity or redundancy p Heavy-duty design IP51 (NEMA 12) for industrial environments p Compact size 2 form factors for an optimized footprint 838 mm deep and 2 widths Fig. 4.3. Key features. Narrow tower Wide tower High availability of high-quality power ● Double-conversion "on-line" technology (VFI as per IEC 62040-3/EN 62040-3) totally isolates the load from network disturbances and fully regenerates the output voltage and frequency to ensure a high level of quality. ● Two separate AC inputs. ● Built-in automatic static bypass and manual maintenance bypass. Optimized battery investment ● User-replaceable, hot-swappable batteries and extendable backup times. - Batteries can be replaced or added on load (Fig 4.4). - Up to 4 external battery cabinets can be added, with up to 6 battery modules per cabinet (1 module = 1 row of 4 batteries). ● Temperature-compensated cyclic battery charging. ● Electronic battery management. Generator friendly ● Soft generator walk-in for 10 seconds means a smaller generator can be used (1.3 to 1.5 x UPS power rating in kW). ● No derating, thanks to the PFC rectifer that maintains PF > 98%. Standard heavy-duty design for industrial environments All MGETM GalaxyTM 3500 units offer characteristics suitable for severe environments. ● Front panel, enclosure and frame all made of 2 mm steel plate. ● Electrostatically applied paint reduces the risk of scratches. ● Easy user-replaceable filters that avoid dust and debris from affecting UPS performance. ● IP51 / NEMA12 degree of protection against sprayed liquids and dust. ● Compact design with a footprint up to 60% smaller than other brands, two enclosure sizes available from 10 kVA to 40 kVA. ● UPS secured to the floor to avoid tipping. ● Mounted on wheels for easy UPS handling. APC by Schneider Electric 05/2009 edition ch. 4 - p.4 MGETM GalaxyTM 3500 UPS (cont.) 2 mm plate IP51 Filters Wheels Fig 4.4. Replaceable filters and heavy-duty design. Simplified maintenance ● Maintenance bypass. A mechanical bypass makes for easy maintenance without shutting down the UPS. ● Modular battery. Extendable for longer backup time. Modules can be easily hotswapped (added or replaced) without tools by trained personnel. ● Withdrawable rack. A support rack can be pulled out from the chassis and held up by two struts. The power module can then be safely pulled out and transferred to a table or platform. ● Access through the front panel. Easy access to the bypass switch and to the battery connections. Maintenance bypass switch Power module in the process of being drawn out Withdrawable rack Battery module (1 module = 1 row of 4 batteries) Fig 4.5. Availability is improved by easy maintenance. Maintenance bypass switch Separate AC inputs Easy access to connections Busbar connections for additional batteries Fig 4.6. Easy access to connectors with an ergonomic work position. APC by Schneider Electric 05/2009 edition ch. 4 - p.5 MGETM GalaxyTM 3500 UPS (cont.) Easy management and operation ● Management via the IT network. The UPS Network Management Card monitors the UPS environment. The UPS is directly managed by the IT network using a web browser. A screen is provided for the main system parameters and an automatic shutdown function protects the data if necessary. ● Backlit LCD display. All status and control information is shown on the backlit display for enhanced visibility. ● Navigation and help keys. These keys facilitate navigation and provide access to the information in the menus (status conditions, operating modes, alarm settings, etc.) as well as to immediate, context-sensitive help. Display Consistent user interface All status and control information on the backlit display Same user interface for all APC UPS, cooling and monitoring products ESC key Return to previous item Help key Context-sensitive help Default LED Red LED goes on if a fault occurs Enter key Status LEDs Select and confirm items Easy navigation in the menu and access to information such as status conditions, changes in the operating mode, settings, etc. Navigation keys Instant overview of system status, indications and alarms, independent of the LCD display Fig 4.7. User-interface display. ● Indications and alarms via LEDs that are independent of the LCD display. ● Audio alarms. ● Consistent user interface. The same interface is used of all APC UPS, cooling and monitoring products. Information screen with graceful-shutdown function that can be automated. UPS Network Management Card with environmental monitoring. Fig 4.8. Management via the IT network. Cost savings ● PFC rectifier does not inject disturbances upstream. - Low level of upstream current distortion, THDI < 5%. - Input power factor PF > 0.98 starting at 50% load. Normal cable sizes and optimum system efficiency, i.e. 1 kVA drawn on the network = 1 kW available for the load. ● Battery charger with temperature compensation. ● Voltage and frequency regulation. ● Wide input-range tolerances suitable for all types of network. - Voltage in 400 V system, range = 304 to 477 V at full rated load. - Frequency range = 40 to 70 Hz. APC by Schneider Electric 05/2009 edition ch. 4 - p.6 MGETM GalaxyTM 3500 UPS (cont.) Options ● Battery cabinets. ● Cabinets for voltage-matching and isolation transformers. ● Empty auxiliary cabinets for installation of transformers or batteries by a third party. ● Maintenance bypass for parallel connection, in a wall-mounted enclosure with indication of switch positions. ● Technical documentation for installers. Installation Two widths ● Height = 1490 mm and depth = 854 mm for all units. ● 352 mm wide unit for 10/15/20 kVA. ● 523 mm wide unit for 10/15/20/30/40 kVA. Parallel connection Up to four units ● Up to four units can be parallel connected for capacity or N+1 redundancy. ● A manual maintenance bypass is sized for the full load power and installed in an external enclosure. ● Baying kit. APC by Schneider Electric 05/2009 edition ch. 4 - p.7 MGETM GalaxyTM 3500 UPS (cont.) Equipment and diagrams MGETM GalaxyTM 3500 single-unit UPSs come fully equipped and offer a wide range of functions. Standard ● PFC three-phase rectifier/charger ● Multi-level three-phase inverter offering very high efficiency ● Static switch ● Manual maintenance bypass ● Backlit LCD display ● Battery monitoring ● Cold-start function on battery power ● Shutdown of battery-charge function during operation on genset power ● Smooth walk-in with 10-second delay for operation on genset power ● Communication cards: - Network Management card with SNMP/web multiprotocols - Dry contacts Optional ● Battery cabinets ● Cabinets for voltage-matching and isolation transformers ● Empty auxiliary cabinets for installation of transformers or batteries by a third party ● Maintenance bypass for parallel configurations, in a wall-mounted enclosure with indication of switch positions ● Baying kit for parallel systems ● Enterprise Power Manager and ISX manager software Fig 4.9. Single-unit UPS. APC by Schneider Electric 05/2009 edition ch. 4 - p.8 MGETM GalaxyTM 3500 UPS (cont.) Electrical and communication characteristics Power rating (KVA at FP= 0.8) (maximum rated apparent output power) Active power (kW) Input (rated values and tolerances) Number of phases Voltage Normal AC input Bypass AC input Frequency Power factor (2) THDI Output (rated values and tolerances) Number of phases Voltage Frequency AC power sync free running Power factor (3) THDU linear load non-linear load Short-circuit capacity of bypass Overload capacity Permissible crest 380 / 400 / 415 V factor Dynamic performance: voltage transients during load step changes Voltage and phase imbalance Maximum frequency variation Efficiency Normal operation 100% load 50% load Battery operation Batteries Type Service life Backup time Possible range 1 module Backup time depending number of 2 modules battery modules 3 modules mounted in the UPS 4 modules (1 modules = 1 row of 4 batteries) Typical recharge time Communication Standard Options 10 15 20 30 40 8 12 16 24 32 3+N (1) 380 / 400 / 415 V 3-phase Tolerances for 400 V: 304 to 477 V at full load; 200 to 477 V at half load (1) 380 / 400 / 415 V ± 10% standard (adjustable to ± 4, 6, 8, 10%) 3-phase 50 or 60 Hz Tolerances 40 to 70 Hz > 0.98 for load > 50% et > 0.95 for load > 15% < 5% at full load 3+N 380 / 400 / 415 V ± 1% 50 or 60 Hz Synchronised with AC input: For 50 Hz : 49 to 51 Hz, 47 to 53 Hz or 40 to 60 Hz. For 60 Hz : 50 to 61 Hz, 57 to 63 Hz or 60 to 70 Hz The synchronisation range can be set on the front panel. 50 or 60 Hz ± 0.02 Hz 0.5 lagging to 0.5 leading 1.5% from 0% to 100% load 3.5% for computer loads as per EN50091-3 / IEC 62040-3 (4) 8 In - 500 ms 110% continuous - 125% for 1 min. - 150% for 30 s Up to 2.7 :1 ± 5% on 0 to 100% or 100 to 0% load step changes recovery time < 100 ms 20° ± 1° for 50% current unbalance 20° ± 3° for 100% current unbalance 0.25 to 1 Hz/s (adjustable via PowerView software) 94.5% 94.4% 94.1% 95.8% 95.3% 95.1% 95.5% 95.7% 94.9% 95.8% 95.5% 95.2% Maintenance-free sealed lead-acid battery with suspended electrolyte Up to 10 years or more than 10 years 6 minutes to 8 hours (with up to 4 additional battery cabinets) 6 min. 18 min. 10 min. 6 min. 32 min. 18 min. 12 min. 6 min. 47 min. 27 min. 18 min. 10 min. 95.6% 95.8% 95.0% 6 min. 5 h - up to 90% ± 5% capacity after complete discharge RS232 Communication cards: - Network Management card (SNMP/web multiprotocols) - Dry contacts (1) Other voltages available on request: 208, 220, 480 V, 660 V… (2) THDI (Total Harmonic Distortion - I for current) (3) THDU (Total Harmonic Distortion - U or voltage) Pn (4) In = rms output current (for PF = 0.8) i.e. In = 0,8Un 3 APC by Schneider Electric 05/2009 edition ch. 4 - p.9 MGETM GalaxyTM 3500 UPS (cont.) Physical characteristics, environment and standards Power rating (KVA at FP= 0.8) (maximum rated apparent output power) Active power (kW) Dimensions and weights Height (mm) Width (mm) Depth (mm) Weight (kg) of UPS frame with power module Weight (kg) of external battery cabinet frame Weight (Kg) of one battery Weight (Kg) of UPS with batteries Environment Noise level (dBA) 1 m from enclosure, at 25°C Degree of protection (as per IEC 60529) Maximum altitude without derating Storage temperature without battery range with battery inverter Operating temperature range battery Standards Construction and safety EMC Harmonics Design, manufacturing Certification and marking APC by Schneider Electric 10 15 20 30 40 8 12 16 24 32 1490 352 (narrow tower) / 523 (wide tower) 838 209 (narrow tower) / 255 (wide tower) 523 272 xxx Each cabinet can house up to 6 battery modules (1 module = 1 row of 4 batteries) 24 (1 module = 1 row of 4 batteries, i.e. 96 kg) The weight of the UPS cubicle with its batteries equals the weight of the frame with its power module plus 96 kg x number of battery modules installed (see Batteries / Backup time) < 43.3 dBA at 70% load (fan at low speed) < 46.2 dBA à < 70% load < 51.3 dBA at 100% load (fan at high speed) < 55 dBA at < 100% load IP 51 1000 m -25°C to +70°C dry heat -10°C to +45°C Full rated load, PF = 0.8: 0 to 40°C mean daily (40°C for 8 hours, 35°C for 24 hours) 20°C to 25°C recommended; overload with PF = 0.8: 0 to 30°C tolerable: 0 to 40°C optimum: +15°C to +25°C (service life cut in half for every 10°C increase above 25°C) IEC 60950-1 IEC 62040-1 and IEC 62040-3 EN 50091-2 IEC 62040-2 / EN 62040-2 EMC directive 2004/108/EC IEC 61000-2-2 / EN 61000-2-2 IEC 61000-3-2/ EN 61000-3-2, IEC 61000-3-4 EN 61000-3-4, IEC 61000-3-5 EN 61000-3-5 ISO14001 / ISO 9001 TüV / CE / LCIE 05/2009 edition ch. 4 - p.10 MGETM GalaxyTM 3500 UPS (cont.) Current and protection characteristics Power rating (KVA at FP= 0.8) (maximum rated apparent output power) Active power (kW) Input currents Currents and measurement conditions 10 15 20 30 40 8 12 16 24 32 ● I1: current at normal AC input N.B. Currents are measured at: - full rated load, PF = 0.8 - rated voltage of normal AC source is of 400 V - battery float charging. For normal AC-source rated voltages of 380 and 415 V, multiply the I1 and Iu values by 1.05 and 0.96 respectively. Max. input current I1 (A) battery recharging Load current Iu (A) Max. current supplied by battery Ibmax (A) APC by Schneider Electric ● Iu: load current (110% of continuous load) ● Ibmax: maximum battery current (at low battery shutdown voltage) Fig 4.10. Input currents 13.7 20.3 27.1 40.6 54.2 16.4 27.7 32.6 54.9 48.8 82 65.2 109.6 24.4 41.1 05/2009 edition ch. 4 - p.11 MGETM GalaxyTM 5000 UPSs Optimised power protection offering high availability and upgradeability for data centres, telecommunications and industrial processes MGETM GalaxyTM 5000 ● 5 power ratings: ● 40 - 60 - 80 - 100 - 120 kVA ● 3-phase input (without neutral) and output ● Parallel connection of up to 6 UPS units, i.e. 6 x 120 = 720 A ● On-line double conversion (VFI) providing voltage regeneration and isolation from the distribution system ● Automatic and manual bypasses ● PFC rectifier with sixpack IGBT modules to avoid upstream distortion (upstream THDI < 3%) and with a PF close to 1 ● Sixpack IGBT modules designed to reduce the number of connections for greater reliability, compactness and easy access from the front ● Sealed lead-acid batteries installed in the UPS cabinet up to 80 kVA ● Backup times from 5 minutes to 8 hours and a fast charger for more secure operation ● Wide input-voltage range from 250 to 470 V to handle disturbed distribution systems ● High overload and discrimination capacity ● Input-current limiting during genset start ● Multilingual, graphic display, high resolution quarter VGA ● Battery monitoring by Digibat (calculation of real backup time and remaining battery life) and block by block monitoring (optional) ● Monitoring and communication possibilities via networks and the web with preventive maintenance (Life Cycle monitoring) ● Low TCO due to an optimised environment (cables, protection, genset compatibility), small footprint, high efficiency and monitoring of multiple UPS units using Enterprise Power Manager software TM Fig. 4.11. MGE GalaxyTM 5000 range Applications MGETM GalaxyTM meets the needs of the most sensitive applications in terms of high energy availability, installation flexibility and control over operating costs: Data centres - high energy quality and availability are combined with a wide range of power-upgrade possibilities from 40 to 720 kVA, easily, in complete safety and without interrupting operations. Telecommunications - uninterrupted, mission-critical operation 24/365 is ensured by redundant architectures. Long backup times are guaranteed by continuous battery monitoring and installation supervision via computer networks or the internet. These systems increase availability and make it possible to plan preventive maintenance. Industrial processes - operation in severe environments is possible due to the robust electrical characteristics capable of handling disturbed distribution systems and a vast catalogue of options and functions (reinforced IP, Ni-Cad batteries, marine versions, etc.). APC by Schneider Electric 05/2009 edition ch. 4 - p.12 MGETM GalaxyTM 5000 UPSs Colour RAL9023 grey. F i g . 4 . 3 6 : Fig. 4.12. For applications such as Data centers, telecommunications and industrial processes Main advantages Highest availability The performance level of MGETM GalaxyTM contributes to providing high-quality energy 24/365 in all environments and for all applications. Double conversion (VFI as per IEC 62040-3/EN 62040-3), providing regeneration of the output voltage and frequency. PFC rectifier with sixpack IGBT modules to avoid disturbances on the upstream system: - low current distortion upstream, THDI < 3% - input power factor (PF) > 0.99. Sixpack component AC Input T U1 i1 U2 i2 U3 i3 Input rectifier Sixpack D Vout THDI < 3 % PF > 0.998 Fig. 4.13. Three-phase rectifier with sixpack IGBT modules, drawing sinusoidal current Digital control of the voltage combined with the charger input(1) and inverter (1) output sixpack IGBT modules ensuring: - a wide input-voltage range from 250 to 470 V, depending on the percent load, suited to all types of applications and disturbed distribution systems - high quality and stability of the output voltage: THDU < 2% on the latest generation of so-called capacitive computer and non-linear loads with a leading power factor of around 0.9 and a high crest factor. - high dynamic performance for load-step changes (< 2% for 100 to 0% and for 0 to 100%), return to the +1% range (rms value) in less than 100 ms. (1) The charger input uses fixed-frequency chopping for stability with respect to the AC input source while the inverter output uses free-frequency chopping to follow fast load variations. See chopping principle in Ch. 5 p. 47. P/Pn 100% 70% Normal AC input Réseau AC normal 250V 340V 470 V Fig. 4.14. Wide input voltage range. (Note: On almost 90% of sites, the UPS percent load is < 75%). APC by Schneider Electric 05/2009 edition ch. 4 - p.13 MGETM GalaxyTM 5000 UPSs (cont.) BackupTMtime remains available due to digital management of batteries: TM The MGE Digibat system checks and enhances battery status, and informs the user. Based on a large number of parameters (percent load, temperature, battery type and age), it controls the battery charge voltage and continuously calculates: - The true available backup time - The remaining service life. The system calculates the optimum cutoff value at the end of the backup time to avoid damaging the battery (excessive discharge) when the percent load is low. This is because when loads are low, the backup time can be very long and result in battery damage without the protection system stepping in. Voltage Backup time Current Percent load Temperature Digibat Calculation Software Battery shutdown warning Service life Battery parameters Fig. 4.15. Digibat. TM TM The MGE B2000 or MGE Cellwatch battery-monitoring systems are available for monitoring each battery string around the clock and predict the risk of failure block by block. - Continuous measurement of the voltage of each block. - Continuous measurement of the internal resistance (Cellwatch only). - Identification of faulty blocks (trend curves). - Possibility of replacing individual blocks. - Remoting of all information via Ethernet, dry contacts or JBus. These options ensure battery availability and maximise its service life. Powerful regulated standard charger separate from the rectifier - supplies the battery with a voltage that is independent with respect to that of the inverter in order to protect the battery and maximise its service life - designed for long battery backup times (several hours) and fast recharging (recharging to 90% of battery capacity in less than 11 hours for a 10-minute battery and in less than 24 hours for a 4-hour battery). Discrimination due to high overload capacity (2.12 In for 1 second) and a permissible crest factor of 3 to 1. Redundancy with up to six parallel UPS units to protect servers requiring high availability. Automatic static switch for no-break transfer to AC power if an internal fault occurs (fault tolerance). UPS servicing and replacement of communication cards and battery modules without interrupting operation. Cold start on battery power if AC power is not available. Input-current limiting during genset start: The charger gradually increases the power drawn on the genset for ten seconds, thus enabling generators equipped with a turbo to ramp up and supply the full rated load. During the 10-second period, the battery supplies part of the necessary energy, using the charger as a chopper to step-up the voltage. Flexibility MGETM GalaxyTM 5000 can meet the upgrade needs of sites, in terms of both power increases and different types of applications, without interrupting operation. Changes in available power - the initial power rating can be multiplied by six through parallel connection, in step with the needs of the application. Tailored batteries (sealed or vented lead acid, Ni-Cad) and backup times from 5 minutes to 8 hours, fast recharging. Many possible architectures with up to six parallel units, isolated redundancy, redundant distribution with an STS (static transfer system). Catalogue of options to cover all safety needs including lightning arrestors, backfeed protection to avoid injecting DC power upstream, industrial adaptation kits, etc. No derating of the active power, whether for inductive or capacitive loads. Operation does not require an input source with a neutral. APC by Schneider Electric 05/2009 edition ch. 4 - p.14 MGETM GalaxyTM 5000 UPSs (cont.) Advanced protection, monitoring and regulation systems A sensor placed directly on the base of the rectifier and inverter sixpack modules monitors the cooling system. This allows an early detection of a malfunction that, so far, could have been destructive. (i.e. body on the heatsink). Then, the UPS transfers without a break to the bypass AC input and sends an alarm to the user. Avoiding the component to be damaged greatly improves the availability of the UPS. Sensor on base of sixpack IGBT module Sixpack IGBT components Fig. 4.16. Direct thermal monitoring of the sixpack IGBT modules. Charge system with independent digital regulation and monitoring devices A microprocessor-based digital system regulates: - the battery voltage using a measurement circuit - the charge current using a measurement circuit. The result is a DC voltage with ripple < 1%. A second circuit, independent of the regulation, monitors the battery voltage and the charge current. Consequently, if the regulation system fails, the monitoring system steps in to shut down the charger and avoid overcharging. This system is required by certain standards (e.g. NFC 58-311). Regulation of the battery voltage depending on the ambient temperature A temperature sensor adapts the charge voltage to the ambient temperature. The measurement is carried out locally (built-in batteries) by a sensor in the UPS cabinet or remotely by a sensor in the battery cabinet. This regulation system takes into account the chemical reaction and prolongs the battery service life. The permissible temperature range (0 to 40°C by default) is set in the personalisation parameters. An alarm is issued for temperatures outside the permissible range. Built-in circuit-breaker protection against deep discharge of the battery MGETM GalaxyTM 5000 is equipped with a circuit breaker to protect the battery. The breaker has an undervoltage release to disable incorrect closing and provoke opening if necessary (e.g. emergency off). It provides battery protection against excessive discharges: when the battery voltage drops below 297 V, the inverter shuts down and the circuit breaker opens. Management of two battery circuit breakers: battery circuit-breaker kit and enclosure MGETM GalaxyTM 5000 can be equipped with and manage two battery circuit breakers. This function can be personalised using the setup software. Battery availability is improved by dividing it into two sections. If one section is faulty, the second is still available. The kit comprising the circuit breaker(s) and the auxiliaries is housed in an enclosure that can be ordered with or without an insulation-monitoring device. Static-switch protection by an RC filter against switching overvoltages and lightning strikes. Fuses at the inverter output ensuring discrimination if a major fault occurs on the inverter output filter. Redundant ventilation as standard, contributing to energy availability in the most critical cases. APC by Schneider Electric 05/2009 edition ch. 4 - p.15 MGETM GalaxyTM 5000 UPSs (cont.) Easy start-up and operation A highly compact UPS for its category, made possible in particular by the use of TM TM IGBTs and the absence of an output transformer, MGE Galaxy 5000 is easy to set up and install. Operation is made easy by: Intuitive user-machine interface - Graphics and pictograms for enhanced safety and comfort: - Black and white graphical display, wide (quarter VGA, 120 x 93 mm) and high resolution (320 x 240 pixels), easy to read under all lighting conditions. - Step-by-step help on the screen for operations. - Animated mimic diagram. - Time-stamping of 2 500 events. Open communication Electronic cards and software can be used to: - Inform on UPS operation and the environment - Protect server data by automatic, clean shutdown of operating systems - Actively supervise an entire set of UPSs. These functions implement different protocols depending on the environment, including dry contacts, the JBus/Modbus protocols for communication with a BMS (Building Management System) and Ethernet for web supervision. Reduction in operating costs and the TCO Total Cost of Ownership (TCO) analysis shows that MGETM GalaxyTM 5000 provides an excellent return on the investment. Reduced installation costs - System components (protection circuit breakers, cables, genset) can be sized to the precise need due to the absence of upstream harmonic currents (THDI < 3%). - System compactness, installation of batteries in the UPS cabinets up to 80 kVA and positioning with the back to the wall all reduce the MGETM GalaxyTM footprint. Reduced operating costs The innovative technology implemented in MGETM GalaxyTM (sixpack IGBT modules, no transformer, high-tech output filter) results in high efficiency, particularly at typical percent loads. MGETM GalaxyTM offers a virtually constant efficiency of up to 94% for percent loads from 25 to 100%. If also has an ECO mode, boosting efficiency up to 97% when the AC source is within tolerances. That means significant savings on the energy bill and in sizing air-conditioning and ventilation systems. Efficiency (%) 100 0 92 25 93 50 94 75 94 100 Load (%) Fig. 4.17. Efficiency. Preventive maintenance: Life cycle monitoring Easy maintenance was a major guideline in designing MGETM GalaxyTM 5000 with: - computer tools for improved servicing and diagnostics - remarkable access to all modules for fast and safe repairs - the Life-cycle monitoring system comprising a range of sensors for preventive maintenance on components such as batteries, fans and capacitors. The system signals the approaching end of component life to the diagnostics tool for timely replacement and enhanced continuity of service for the protected application. APC by Schneider Electric 05/2009 edition ch. 4 - p.16 MGETM GalaxyTM 5000 UPSs (cont.) Installation Compact design with total access through the front MGETM GalaxyTM 5000 implements the latest technical and mechanical advances in terms of electrical and power-electronic components. The significantly reduced number of components makes possible: A particularly compact solution, but that ensures easy access for maintenance Integration of many functions in a single cabinet (harmonic filtering, lightning arrestor, backfeed protection and redundant ventilation) Integration of the battery up to 80 kVA (5 minutes backup time), in lateral compartments. Two types of UPS cabinets UPS cabinet with built-in battery, dimensions H x W x D: 1900 x 1110 x 850 mm, up to 80 kVA /5 minutes, 60 kVA /10 minutes, 40 kVA / 15 minutes 30 kVA / 30 minutes of backup time. This innovative design makes for easy handling and connections, while maintaining access through the front, a requirement for fast maintenance. Batteries can be hot swapped (inverter running). UPS cabinet without battery (in separate cabinet), dimensions H x W x D: 1900 x 710 x 850 mm, same dimensions for the entire range from 40 to 120 kVA Battery cabinets - two widths, 710 and 1010 mm For 40 - 60 kVA: H x W x D: 1900 x 710 x 850 mm For 80 - 100 - 120 kVA: H x W x D: 1900 x 1010 x 850 mm. Installation in a limited-access room (qualified personnel). Can be positioned back to the wall, 250 mm minimum overhead clearance. 1110 mm 710 mm Fig. 4.18. UPS cabinet with or without built-in battery. Fig. 4.19. Two widths for battery cabinets. > 250 mm > 1000 mm 710 mm Fig. 4.20. No major constraints. APC by Schneider Electric 05/2009 edition Fig. 4.21. Installation with separate battery cabinets. ch. 4 - p.17 MGETM GalaxyTM 5000 UPSs (cont.) Parallel connection MGETM GalaxyTM 5000 is designed for parallel connection of units with identical ratings. Active redundancy with two integrated parallel UPS units In this case, parallel connection of a second unit is intended to increase the availability of energy. Two identical UPS units, each with its built-in static and manual bypass, supply the load at the same time in parallel (hence the term active redundancy). However, each unit can supply the load alone if the other is stopped. This type of redundancy is called 1/2. The second unit can be connected in parallel without interrupting the load. Connection is possible with separate or common normal and bypass AC inputs. Normal AC input Module 1 (a) Bypass AC input Normal AC input Normal AC input Bypass AC input Bypass AC input Load Bypass AC input Module 2 Module 1 Module 2 Normal AC input Load (b) Fig. 4.22. Active redundancy with two integrated parallel UPS units, with separate (a) or common (b) normal and bypass AC inputs. Parallel connection of 3 to 6 UPS units MGETM GalaxyTM 5000 also allows parallel connection of 3 to 6 integrated parallel UPS units. Parallel connection with active redundancy for configurations with up to 4 UPS units (i.e. up to 2 redundant units). Each modular unit includes a static bypass, with a common external maintenance bypass unit sized for the maximum power. The UPS units share the load to be supplied. If one UPS unit stops, the others continue to supply the load. Parallel connection without redundancy for up to 6 UPS units. This requires a common external maintenance bypass unit. The UPS units share the load to be supplied. If one UPS unit stops, the other are not sufficient to supply the load and the entire UPS system stops. Bypass AC input EXTERNAL BYPASS UNIT Normal AC input Normal AC input UPS1 P1(kVA) Normal AC input UPS2 P1(kVA) UPS3 P1(kVA) Load Fig. 4.23. Active redundancy with 3 units and external bypass unit. Maximum number of UPS units connected in parallel, depending on the type of bypass Rated power (kVA) of each unit 40 60 80 100 120 150 kVA enclosure 3 2 1 1 1 360 kVA cubicle 6 6 4 3 3 600 kVA cubicle 6 6 6 6 4 APC by Schneider Electric 05/2009 edition ch. 4 - p.18 MGETM GalaxyTM 5000 UPSs (cont.) Diagram and functions MGETM GalaxyTM 5000 single UPS units offer the following equipment and functions. Standard ● Three-phase PFC rectifier/charger with sixpack IGBT modules ● Three-phase IGBT inverter with PWM chopping (free-running frequency) and no output transformer ● Automatic bypass (static switch) ● Manual maintenance bypass. ● Multilingual high-resolution quarter VGA graphic display ● Event logging and time-stamping of the 2500 most recent events ● LED-based mimic diagram ● Built-in batteries (up to 80 kVA / 5min) ● Battery protected against excessive discharges by a circuit breaker ● EMC C3 monitored distribution ● 1 relay card with dry contacts, 2 inputs and 6 outputs, 250 V 2 A ● DigiBat Battery Monitoring, with calculation of the true backup time ● Cold start on battery power ● Rectifier walk-in and current limiting to ensure compatibility with gensets ● Battery charger adapts to ambient temperature of battery room ● Redundant ventilation for the static switch ● Terminal block for EPO (emergency power off) ● Sequential start of UPS units (parallel configuration) Optional: ● ECO mode ● Connection from the top ● Galvanic isolation transformer ● Lightning arrestor (built into the UPS cabinet) ● Backfeed function to protect the upstream source from battery faults ● B2000 or Cellwatch battery monitoring ● Second relay card with dry contacts, 2 inputs and 6 outputs ● Communication cards: - 2 dry contact and/or remote shutdown contacts - SNMP/Web Network Management card - JBus/Modbus RS232 and RS485 - 6 relay contacts 250 V 2 A - RS232 ● Supervision and shutdown software: - Enterprise Power Manager - Network shutdown module Fig. 4.24. Single UPS unit APC by Schneider Electric 05/2009 edition ch. 4 - p.19 MGETM GalaxyTM 5000 UPSs (cont.) Electrical characteristics Power rating Pn (KVA at PF= 0.8) (rated apparent output power) Active power (kW) Input (rated values and tolerances) Number of phases Voltage Normal AC input Frequency Power factor Bypass AC input Utility 50% Pn 75 to 100% Pn (2) THDI Max. upstream short-circuit power 40 60 80 100 120 32 48 64 80 96 3ph + N or 3ph (for operation without neutral) (1) Un = 400 V ± 15 % i.e. 340 to 470 V at Pn and 250 V à 470 V to 70 % Pn (except with backfeed) (1) 400 V ± 10 % or ± 15 % (option) 50 or 60 Hz ±10 % i.e. 45 to 65 Hz 0.999 0.992 0.999 0.998 < 3% at Pn, < 5% from 25 to 75% Pn 20 kA (input protected by 125 A 30 kA (protected by 125 A fuses) fuses) See the "input and output currents" table below Currents Output (rated values and tolerances) Number of phases 3 + N or 3ph (for operation without neutral) Voltage 380 / 400 / 415 V ± 1% 3-phase at 50 Hz (rated rms output 380 / 400 ± 1% 3-phase at 60 Hz value) Fine adjustment possible via user-machine interface to Un ± 3% Frequency AC power sync 50 or 60 Hz ± 0.5 Hz (adjustable) free running ± 0.25 Hz (adjustable from 0.25 to 2 Hz in 0.25 Hz steps) Power factor 0.8 for inductive and resistive loads - 0.9 on capacitive loads (3) THDU linear load 1% ph/ph, 1.5% ph/N (RL loads at cos = 0.8 and 0.9) non-linear load 2% ph/ph, 3.5% ph/N (RCD loads as per standard ENV 50091-3) (4) Short-circuit capacity of inverter 2.7 In peak for 150 ms Overload capacity of inverter 125% for 10 min. - 150% for 1 min. - 220% for 1s (4) Overload capacity Static switch Ipeak / In for 20 ms Single UPS unit 22 15 29 23 19 Parallel config. 58 39 38 30 25 Permissible crest factor Up to 3 : 1 ± 2% on 0 to 100% or 100 to 0% load step changes Dynamic performance: voltage transients recovery time (return to ± 1%) < 100 ms during load step changes Maximum frequency variation 1 Hz/s or 2 Hz/s (adjustable) Efficiency On-line mode 100% Up to 94% 50% Up to 92% ECO mode 100% Up to 97% Conditions for transfer without interruption between normal and bypass lines Bypass source voltage tolerances Un ± 10% before bypass to normal transfer Un - 20% to + 15% after bypass to normal transfer (load supplied by inverter) Bypass source frequency tolerances ± 8% of 50 or 60 Hz as standard adjustable to ± 0.5% ± 1%, ± 2%, ± 4%, ± 8% Phase difference tolerances 3 degrees Transfer with interruption If any parameter is outside tolerances, transfer can be carried out with an adjustable (bypass source outside tolerances) interruption of 13 ms to 1 s, after authorisation by the user via the operator keypad Battery Type Sealed lead-acid or optional vented lead-acid or nickel-cadmium Service life Up to 10 years or more Backup time 5 - 10 - 15 (standard) or 1 - 2 - 4 - 8 hours (optional) Built-in battery (max. avail. backup time) 5 min. for 80 kVA, 10 min. for 60 kVA, 15 min. for 40 kVA Recharge time (hours) 5 minutes 10 9 10 9 9 for different backup 10 minutes 10 12 11 11 11 times (complete 15 minutes 12 12 12 13 13 discharge at Pn/2 and recharge to 90%) (1) Other voltages available on request (2) THDI (Total Harmonic Distortion - I for current) (3) THDU (Total Harmonic Distortion - U for voltage) (4) In = rms output current (for PF = 0.8) i.e. APC by Schneider Electric In = Pn 0,8Un 3 05/2009 edition ch. 4 - p.20 MGETM GalaxyTM 5000 UPSs (cont.) Communication Power rating Pn (KVA at PF= 0.8) (rated apparent output power) Active power (kW) Human-Machine Interface (HMI) Standard Communication Standard Options Software Standard Options 40 60 80 100 120 32 48 64 80 96 Black and white graphical display - quarter VGA (120 x 93 mm) - high resolution (320 x 240 pixels) Operating LEDs (load protected, minor fault, major fault) On and Off buttons Help key Function keys Menu key Mimic panel with status LEDs 1 relay card with dry contacts, 2 inputs and 6 outputs, 250 V 2 A A second relay card with dry contacts, 2 inputs and 6 outputs Communication cards: - SNMP/Web Network Management card - JBus/ModBus RS232 or RS485 - SNMP / Ethernet - SNMP/Web Network Management card - 2 ports with dry contacts and/or remote shutdown Solution Pac Enterprise Power Manager Physical characteristics - dimensions and weight Power rating Pn (KVA at PF= 0.8) 40 60 (rated apparent output power) Active power (kW) 32 48 UPS cabinet with built-in battery Width 1110 mm H x W x D (mm) 1900 x 1110 x 850 Weight (kg) Without battery 453 (depends on backup 5 minutes 738 888 time) 10 minutes 888 975 15 minutes 975 UPS cabinet without battery Width 710 mm H x W x D (mm) 1900 x 710 x 850 Weight (kg) 400 Battery and auxiliary cabinets Width 710 mm H x W x D (mm) 1900 x 710 x 850 Weight (kg) 135 Width 1000 mm H x W x D (mm) 1900 x 1010 x 850 Weight (kg) 150 Combinations of battery cabinets for given backup times Width and weight of > 5 min W(mm) cabinets with batteries kg depending on the > 10 min W(mm) backup time kg >15 min W(mm) 710 kg 885 > 30 min W(mm) 710 1010 kg 882 1307 Bypass enclosure or cubicle for parallel connection 150 kVA enclosure, H x W x D (mm) / kg 1000 x 800 x 303 / 71 Max. number of parallel UPS units 3 2 360 kVA cubicle, H x W x D (mm) / kg 1900 x 715 x 825 / 190 Max. number of parallel UPS units 6 6 600 kVA cubicle, H x W x D (mm) / kg 1900 x 1015 x 825 / 280 Max. number of parallel UPS units 6 6 APC by Schneider Electric 05/2009 edition 80 100 120 64 80 96 1050 520 710 885 1010 1142 2x710 1764 710 885 1010 1142 1010 1307 710+1010 2439 710 985 1010 1307 2x710 1764 2x1010 2742 1 1 1 4 3 3 6 6 5 ch. 4 - p.21 MGETM GalaxyTM 5000 UPSs (cont.) Physical characteristics - environment and standards Power rating Pn (KVA at PF= 0.8) (rated apparent output power) Active power (kW) Environment Colour of cabinets Degree of protection (as per IEC 60529) Noise level (dBA) ISO 3476 Heat losses (kW) Single UPS 40 60 80 100 120 32 48 64 80 96 RAL 9023 IP20 and anti-dust filter are optional 65 3150 4350 4900 6150 7350 2700 3500 4000 4750 5550 2300 2700 3400 3700 3950 100% load Single UPS 75% load Single UPS 50% load Fan throughput Maximum altitude 3 m /h without derating with derating Storage temperature without battery range with battery Operating temperature inverter range battery Relative humidity Standards Construction and safety EMC Harmonics Design, manufacturing Certification and marking APC by Schneider Electric 1332 1332 2556 2556 2556 1000 m. 0.85 at 1500 m - 0.79 at 2000 m - 0.75 at 2300 m - 0.69 at 3000 - 0.59 at 4000 m -25°C to +70°C dry heat -10°C to +45°C Full rated load, PF = 0.8: 0 to 40°C 20°C to 25°C recommended for optimum battery operation tolerable: 0 to 40°C optimum: +15°C to +25°C (service life cut in half for every 10°C increase above 25°C) 45% to 75% without condensation at ambient temperature IEC 60950-1 IEC 62040-1 IEC 62040-3 EN 50091-2 IEC 62040-2 / EN 62040-2 EMC directive 2004/108/EC IEC 61000-2-2 / EN 61000-2-2 IEC 61000-3-2/ EN 61000-3-2 IEC 61000-3-4 EN 61000-3-4 IEC 61000-3-5 EN 61000-3-5 ISO 14001 / ISO 9001 TÜV / CE / LCIE 05/2009 edition ch. 4 - p.22 MGETM GalaxyTM 5000 UPSs (cont.) Current and protection characteristics Power rating Pn (KVA at PF= 0.8) (rated apparent output power) Active power (kW) Input currents 40 60 80 100 120 32 48 64 80 96 Currents and measurement conditions ● I1: current at normal AC input N.B. Currents are measured at: ● full rated load, PF = 0.8 ● rated voltage of normal AC source is of 400 V ● battery float charging. For normal AC-source rated voltages of 380 and 415 V, multiply the I1 and Iu values by 1.05 and 0.96 respectively. ● Iu: load current ● Ibmax: maximum battery current Fig 4.25. Input currents. Max. input current I1 (A) for 5 to 10 minutes 53 78 of backup time, battery recharging 104 130 155 Load current Iu (A) Max. current supplied by battery Ibmax (A) 116 240 145 300 174 360 APC by Schneider Electric 58 120 87 180 05/2009 edition ch. 4 - p.23 MGETM GalaxyTM PW UPSs Presentation Protection of medium power computer rooms and industrial and commercial sites MGETM GalaxyTM PW ● 2 power ratings: 160 - 200 kVA ● Three-phase input and output ● Parallel connection of up to four UPS units, i.e. up to 800 kVA ● On-line double conversion (VFI) ● Static switch and manual bypass ● Backup times from 8 minutes up to 8 hours ● Sealed/vented lead-acid batteries or Ni/Cad batteries, with service lives of 10 years or more TM Fig. 4.25. MGE GalaxyTM PW range. Applications MGETM GalaxyTM PW is designed to meet the high-availability needs of commercial and industrial-process equipment (automation, instrumentation, medical equipment, emergency lighting). Colour Light grey RAL 9002. For other colours, please consult us. Main features Flexibility MGETM GalaxyTM PW can adapt to the environment and to its changes: Wide range of backup times, from 8 minutes to 8 hours. Upgradeable for more power or improved availability: - parallel connection of up to four UPS units, - hot-standby configurations, - synchronisation of redundant UPS units is available using synchronisation modules, thus enhancing availability ever further. Wide input-voltage range for improved compatibility and fewer transfers to battery power. Back to the wall possible. Possibility of direct integration of an isolation transformer and harmonics filters; Possible connection through the top. Fig. 4.26. Dimensions APC by Schneider Electric 05/2009 edition ch. 4 - p.24 MGETM GalaxyTM PW UPSs (cont.) Availability Through its design, the priority for MGETM GalaxyTM PW is always to keep power flowing to the application: On-line double-conversion technology (VFI as per IEC 62040-3/EN 62040-3), that completely regenerates the power signal and the frequency, and guarantees constant power quality whatever the conditions on the distribution system. Automatic bypass for no-break transfers of the load to the bypass AC input if an internal anomaly occurs (fault tolerant). N+1 redundancy with up to four UPS units (3+1). Cold-start function for start-up of applications on battery power even during a utility power outage. Control of harmonics and energy savings Complete control of upstream harmonics by integrated harmonic filtering: - Elimination of input-current harmonics (THDI < 4%), - High power factor (0.95), - Total compatibility with engine generator sets. Energy and equipment savings The above characteristics produce savings: - Lower energy bills - Smaller size of installation equipment - Smaller size of engine generator sets. High efficiency Efficiency up to 97%, depending on the operating mode. Simple and clear user interface The MGETM GalaxyTM PW user interface is designed to ensure secure operations and complete monitoring of information. Multi-lingual graphic display (15 languages including Chinese) providing clear information on measurements, diagnostics and alarms, Animated mimic panel with LEDs, Parameter analysis: analysis of 150 different parameters. Time-stamping and logging of the last 500 events. Battery meter: indication of the battery backup time. TM TM MGE Galaxy PW also offers extensive communication possibilities with the electrical and computer environments: Media contact 11 communication port + 6 dry contacts 250 V 5 A. Three additional ports (optional) for the installation of communication cards. - Network management card, SNMP/Web format - JBus/ModBus RS232 and RS485 - 2 ports with dry contacts and/or remote shutdown - 6 relay contacts 250 V 2 A - Modem for Teleservice Emergency power off (EPO) terminal block. LED remote-indications unit (optional). Compatible with management and supervision software for APC by Schneider Electric devices: - Enterprise Power Manager - Network shutdown module Environment Sensor (optional) for the SNMP/Web card: monitoring of temperature/humidity and status of two contacts via SNMP or the web. Initiates equipment shutdown if necessary. Voltage Backup time Current Digibat Percent load Calculation Software Temperature Battery shutdown warning Service life Battery parameters Fig. 4.27. Graphic display. APC by Schneider Electric 05/2009 edition Fig. 4.28. MGE TM TM Digibat . ch. 4 - p.25 MGETM GalaxyTM PW UPSs (cont.) MGETM DigiBatTM for advanced battery management MGETM DigiBatTM Battery Monitoring optimises the battery service life and continuously maintains a high degree of battery availability through the functions listed below: Increased battery service life by taking into account the manufacturer parameters, with adaptation of the charge voltage to ambient temperature changes. Precise measurement of the true backup time depending on the age of the battery, the room temperature and the percent load on the UPS. Calculation of the remaining battery service life. Protection against deep battery discharge. Limitation of the charge current (0.05 C10 to 0.1 C10). Automatic tests at regular intervals. Backfeed protection (optional) to protect users from the flow of power upstream toward the distribution system during operation on battery power. MGETM B2000 or MGETM Cellwatch battery-monitoring systems (option or part of a maintenance contract) for battery monitoring, battery cell by battery cell. Optimum voltage quality MGETM GalaxyTM PW offers high performance to handle the increasing number of non-linear loads: IGBT technology with free-running frequency, guaranteeing a level of harmonic distortion in the output voltage under 3%. Voltage transients under 2% for 100% load step changes on battery power. Capacity to supply loads with crest factors up to 6.6 : 1. Capacity to operate under unbalanced load conditions (up to 100%). Total compatibility with engine-generator sets MGETM GalaxyTM PW offers total operating compatibility with engine generator sets. Elimination of upstream harmonics: complete range of passive and active harmonics filters. Sequential start-up of parallel-connected UPS units to limit the inrush current. Limitation of the power drawn during operation on the engine generator set. Gradual start of UPS units when the engine generator set steps in to supply power (6 to 10 second walk-in). Fig. 4.29. Walk-in for UPS units when the engine generator set starts to supply power. Installation Installation back to the wall with connection through the top ● Back to the wall installation No lost space. ● Possibility of connection through the top APC by Schneider Electric 05/2009 edition ch. 4 - p.26 MGETM GalaxyTM PW UPSs (cont.) Fig 4.30. Installation back to the wall Parallel connection Parallel connection of up to 4 UPS units with or without redundancy Up to 4 Galaxy PW UPSs can be connected in parallel for a maximum power rating of 4 x 200 = 800 kVA. Parallel configurations can include n+1 or n+2 redundancy, i.e. 1 or 2 redundant UPS units. For easy maintenance of parallel configurations, a manually operated mechanical bypass is provided. ● Integrated in each UPS for configurations with 2 units in parallel ● Installed in a separate "maintenance bypass" cabinet for configurations with 3 or 4 units in parallel. APC by Schneider Electric 05/2009 edition ch. 4 - p.27 MGETM GalaxyTM PW UPSs (cont.) Diagram and functions MGETM GalaxyTM PW single UPS units offer the following equipment and functions: Standard ● Three-phase rectifier/charger ● Three-phase inverter with PWM chopping (free-running frequency) ● Automatic bypass (static switch) ● Manual maintenance bypass. ● Graphic display with 15 languages, timestamping and logging of events ● Media Contact 11 communication port. ● Three communication ports ● DigiBat Battery Monitoring, function with precise measurement of the true backup time ● ECO mode ● Cold start on battery power ● Interruption of battery charge during operation on engine generator set power ● UPS walk-in with time delay when an engine generator set starts to supply power Optional ● Active harmonics filter or passive filter (noncompensated with contactor or compensated) ● Backfeed function to protect the distribution system from battery faults ● B2000 or Cellwatch battery-monitoring system ● Communication cards: - SNMP Network Management card - JBus/ModBus RS232 and RS485 - 2 ports with dry contacts and/or remote shutdown - 6 relay contacts 250 V 2 A - RS232 - modem for Teleservice ● Software: - Enterprise Power Manager - Shutdown module Fig. 4.31. Single UPS unit. APC by Schneider Electric 05/2009 edition ch. 4 - p.28 MGETM GalaxyTM PW UPSs (cont.) Electrical characteristics and communication Power rating (kVA at PF = 0.8) 160 200 (rated apparent output power) Active power (kW) 128 160 Input (rated values and tolerances where applicable) Number of phases 3+N (1) Voltage Normal AC input 380 / 400 / 415 V ± 10 % (adjustable ± 15 %) 3-phase (1) Bypass AC input 380 / 400 / 415 V ± 10 % (adjustable ± 15 %) 3-phase Frequency 50 or 60 Hz ± 10 % Power factor up to 0.95 with THM option (2) THDI < 4 % with THM option, < 5 % with LC filter Currents See the "input and output currents" table below Output (rated values and tolerances where applicable) Number of phases 3+N Voltage 380 / 400 / 415 V ± 1 % (adjustable ± 15 %) (1) Frequency AC power sync 50 or 60 Hz ± 0.5 Hz (adjustable from 0.5 to 2 Hz in steps of 0.25 Hz) free running ± 25 Hz (adjustable from 0.25 to 2 Hz in steps of 0.25 Hz) Power factor cos φ up to 0.9 leading (3) THDU linear load 2 % ph/N reference non 2 % ph/ph, 3 % ph/N linear load (4) Short-circuit capacity (without bypass) (A) 2.33 In - 1 s (4) Bypass short-circuit capacity 10 In - 20 ms Overload capacity 125 % for 10 min. - 150 % for 1min. Crest factor Up to 3 :1 Voltage transients during ± 2 % on 0 to 100% or 100 to 0% load step changes recovery time < 20 ms for linear loads and < 50 ms for non-linear loads load step changes Voltage and phase imbalance 1.5 % and 2 degrees for 50% current imbalance Maximum frequency variation 1 Hz/s Efficiency Percent load 100 % up to 93 % 50 % up to 93 % In ECO mode 100 % up to 94 % 50 % up to 96 % Conditions for transfer to AC bypass Acceptable difference in voltage + 10 %, - 12% Synchronisation frequency range ± 0.5 Hz to ± 2 Hz adjustable in steps of 0.25 Hz Maximum phase shift 3 degrees Battery Type Sealed lead-acid (option: vented lead-acid or ni-cad) Service life Up to 10 years or more than 10 years Backup time 8 - 10 - 15 - 20 - 30 min. (60 min. or more on request) Communication Standard 1 Media Contact 11 communication port 3 ports for communication cards Options Communication cards: - SNMP Network Management card - JBus/ModBus RS232 and RS485 - 2 ports with dry contacts and/or remote shutdown - 6 relay contacts 250 V 2 A - RS232 - modem pour Teleservice LED indication unit (1) other voltages on request 208, 220, 480 V, 660 V… (2) THDI (Total Harmonic Distortion - I for current) (3) THDU (Total Harmonic Distortion - U for voltage) Pn (4) In = output current (for PF = 0.8), i.e. In 0.8 Un 3 APC by Schneider Electric 05/2009 edition ch. 4 - p.29 MGETM GalaxyTM PW UPSs (cont.) Physical characteristics, environment and standards Power rating (kVA at PF = 0.8) 160 (rated apparent output power) 200 Active power (kW) 128 160 Dimensions and weight of UPS Height (mm) 1900 Width (mm) 1215 Depth (mm) 825 Weight without option (kg) 1200 Dimensions and weight battery cabinet: height 1900 mm - depth 825 mm Backup time Width (mm) 1430 2030 10 min. - 5 yr Wt. with batt. (kg) 2110 2785 Backup time Width (mm) 1430 2030 30 min. - 5 yr Wt. with batt. (kg) 4295 5670 Environment Noise level (dBA) < 65 Heat losses Single UPS 10.7 14.3 at 100 % load (kW) (1) Degree of protection (as per IEC 529) IP205 Maximum altitude without derating 1000 m Temperature range without battery - 25°C to + 70°C dry heat for storage with battery - 10°C to + 45°C Temperature range inverter at full rated load, PF = 0.8: 0 to 40°C mean daily (40°C for 8 hours, 35°C for 24 hours), for operation 20 to 25°C recommended, for overload conditions, PF = 0.8: 0 to 30°C battery possible: 0 to 40°C (40°C for 8 hours, 35°C for 24 hours) optimum: + 15°C to + 25°C (service life is reduced by half for every 10° above 25°C) Standards Construction and safety IEC 60950-1 IEC 62040-1 IEC 62040-3 EMC EN 50091-2 IEC 62040-2 / EN 62040-2 EMC directive 2004/108/EC Harmonics IEC 61000-2-2 / EN 61000-2-2 IEC 61000-3-2/ EN 61000-3-2 IEC 61000-3-4 EN 61000-3-4 IEC 61000-3-5 EN 61000-3-5 Design, manufacturing ISO 14001 / ISO 9001 Certification and marking TÜV / CE / LCIE (1) Other IPs on request APC by Schneider Electric 05/2009 edition ch. 4 - p.30 MGETM GalaxyTM PW UPSs (cont.) Currents and protection characteristics Power rating (kVA at PF = 0.8) (rated apparent output power) Active power (kW) Input and output currents 160 200 128 160 Currents and measurement conditions ● I1 : input current on Normal AC input Currents and measurement conditions ● Iu : load current N.B. These currents are measured for: - full rated load for PF = 0.8; - a rated Normal AC input voltage of 400 V; - battery float charging. For rated Normal AC input voltages of 380 V and 415 V, multiply the indicated I1 and Iu values by 1.05 and 0.96 respectively. ● Ibmax. maximum battery current Fig. 4.32. Input and output currents. Max. input current I1 (A) for 10 min. backup 288 time - batteries charging Load current Iu (A) 243 Max. battery output current Ibmax (A) 410 APC by Schneider Electric 05/2009 edition 357 303 512 ch. 4 - p.31 MGETM GalaxyTM 7000 UPS Presentation Protection for your mission-critical high-power applications up to several MVA, in all distribution systems MGETM GalaxyTM 7000 ● 4 power ratings: 250 - 300 - 400 - 500 kVA ● Frequency converter versions ● 3-phase in (without N) and out (with N) ● On-line double conversion (VFI) ● Automatic and manual bypasses ● Wide input-voltage range from 250 V (30% load) to 470 V (100% load) to handle disturbed distribution systems ● Input-current limiting during genset start (soft start) ● IGBT-based, PFC sinusoidal-current input rectifier: THDI < 5% and PF > 0.99 starting at 50% load ● Phase-sequence check to ensure power availability ● Separate charger so battery voltage does not depend on the AC source ● Backup times from 5 minutes to 8 hours with a rapid charger (recharge < 6 hours for 10 minutes backup time) ● Cold start on battery power ● Output PF = 0.9 ● Output voltage adjustable 3% to take into account voltage drops in the cables ● High short-circuit capacity for good discrimination up to 3 In ● Compatible with all loads: capacitive computers, resistive, motors, etc. ● Efficiency of 94.5% in normal mode, 97% in ECO mode ● Power rating increased by 7.5% for ambient temperatures below 20°C ● Power components have independent, redundant ventilation with fault detection ● IP 20 and IP32 versions ● Backfeed option for IEC 62040-1-2 compliance ● Multi-standard communication cards with Jbus/Modbus and Ethernet 10/100 Mbps + https pages for Web supervision, NMS, NMTC card for Teleservice ● HMI with graphical interface, 19 languages, measurements, alarms, ● Eco-design and eco-manufacturing for statistics, 2500 time-stamped events ● Digital battery management by sustainable development DigiBatTM (calculation of real backup time ● Eco-design ISO 14040 and 14060 and remaining battery life) and block by ● Site and R&D certified ISO 14001 block monitoring ● Manufacture with over 91 % recyclable ● Parallel connection of up to 8 UPS units i.e. 8 x 500 kVA = 4 MVA materials ● Capacity to recover products at the end ● Possibility of external synchronisation ● Many architectures: integrated parallel, of their service life and provide proof of parallel with SSC, with STS, compliant destruction by a certified organisation with ANSI/NEMA 942 TIER IV ● Alarm signalling loss of redundancy ● Optimised maintenance with Life Cycle Monitoring for predictive maintenance, with front access to all assemblies Fig. 33. MGE APC by Schneider Electric TM TM Galaxy 7000 range. 05/2009 edition ch. 4 - p.32 MGETM GalaxyTM 7000 UPS (cont.) Applications Three-phase MGETM GalaxyTM 7000, 250 to 500 kVA (up to 4 MVA in parallel configurations), includes cutting-edge technologies for high-power applications. MGETM GalaxyTM 7000 offers optimised performance for data centers, infrastructure and industrial processes. It increases the productivity of these applications by providing continuity of service through secure supply solutions that are flexible, TM TM adaptable and upgradeable. MGE Galaxy 7000 provides high-quality energy, compatible with all loads, with a very high level of availability. The variety of architectures meets the specific needs of each installation and allows easy upgrading. The communication capabilities and proactive services provided by APC by Schneider Electric, the most complete and available worldwide, make for highly effective maintenance. Data Centers. The strategic and economic importance of data centers made it necessary to set up the ANSI/TIA site typology (TIER I to IV). It presents the necessary functions of the major components, including supply via UPSs, to ensure consistency and obtain a high level of overall availability. MGETM GalaxyTM 7000, through its design and many possibilities for parallel connection, as well as its compatibility with STS (static transfer switch) systems, meets TIER IV requirements for fault-tolerant sites offering the highest level of availability (99.995%). Combined with STS units, MGETM GalaxyTM 7000 can supply energy via two or three different channels for dual or triple-attach applications and also offers supervision, network administration and remote-control solutions. MGETM GalaxyTM 7000 is ideal for the large (over 500 square metre) data centers of banks, insurance companies, internet and colocation services, telecoms, etc. where 24/365 operation is mandatory and preventive maintenance and upgrades must not require system shutdown. Infrastructure and buildings. Service continuity is also required for infrastructure (airports, ports, tunnels) as well as the operation and technical monitoring (via SCADA and BMS systems) of shopping centres, hospitals, office buildings, etc. MGETM GalaxyTM 7000 is perfectly suited to the needs of these communicating, frequently upgraded applications thanks to its power ratings, extension possibilities and communication capabilities. Industrial processes. Operation in industrial environments requires equipment capable of maintaining processes, without failure, under difficult conditions, including dust, humidity, vibrations, major variations in temperature, etc. Due to its high TM TM electrical and mechanical level of performance, MGE Galaxy 7000 meets these specific needs. Technical files are available for all the applications specified by design offices, including Ni-Cad batteries for the chemical and petrochemical industries, high IP values, heavy-duty reinforced cabinets, dust filters, marine configurations, rated voltages up to 440 V, etc. The APC by Schneider Electric design office, in conjunction with a specialised industrial organisation, can also handle uncommon conditions, e.g. outdoor installations, anti-vibration bases for marine applications, special paints with the corresponding labels, etc. Fig. 34. Applications such as data centers, infrastructure and industrial processes. Colour Light grey RAL 9023. APC by Schneider Electric 05/2009 edition ch. 4 - p.33 MGETM GalaxyTM 7000 UPS (cont.) Strong points An innovative range offering a high degree of power availability for high-power installations and for all types of distribution systems MGETM GalaxyTM 7000 design combines the best technology (double conversion) with the most recent innovations to supply high-quality power, available 24/365, to high-power applications, whatever the situation in the distribution system. Double conversion technology (VFI as per IEC 62040-3/EN 62040-3). This is the only technology that insulates the load from the upstream network and completely regenerates the output voltage, thus providing high-quality, stable power. IGBT-based, PFC sinusoidal-current input rectifier. The rectifier draws sinusoidal current, without any reactive power, thus avoiding disturbances upstream by reducing harmonic reinjection. - Very low current total harmonic distortion THDI, less than 5%. - Input power factor (PF) greater than 0.99 from 50% load upwards. These performance levels, combined with the three-phase input not requiring a neutral, offer substantial savings in terms of cables and equipment. DualPack component AC source T U1 i1 U2 i2 U3 i3 PFC input-rectifier D Vo THDI < 5 % PF > 0.998 Fig. 35. Three-phase, PFC sinusoidal-current rectifier, with DualPack IGBTs. Battery charger separated from the AC input. The chopper is supplied via the rectifier output and is thus protected against fluctuations on the AC input. Battery recharge is adjusted as a function of the temperature. A check on the phase sequence is run to protect the power system from the effects of incorrect connections. Wide input-voltage (250 to 470 V) and frequency (45 to 65 Hz) range. This is made possible by double-conversion technology and the PFC rectifier which is compatible with all sources and with disturbed distribution systems (voltages as low as 250 V for 30% load). P/Pn Load PF = 0.9 100% 30% Normal AC input 250 V 380 V 470 V Fig. 36. Wide input-voltage range. Soft start. This system provides total compatibility with gensets through gradual start of the rectifier, in addition to a PF of 0.99. It makes it possible: - when AC power is absent, to progressively transfer the load from the battery to the genset - when the normal AC source returns to tolerances, to delay transfer from the battery to the rectifier, thus avoiding excessive variations on the AC source. - in a parallel system, to set up sequential start-up of the inverters. I Rectifier/charger In alk W -in t Time delay 6 to 10 seconds Fig. 37. Soft start walk-in ramp with time delay. APC by Schneider Electric 05/2009 edition ch. 4 - p.34 MGETM GalaxyTM 7000 UPS (cont.) Cold start on battery power if the AC source is absent or disturbed, even in parallel systems. High-quality output voltage (380, 400, 415 or440 V) for all types of loads with: Overload ratio I/In - THDU < 3% - output PF = 09 for all types of load. The range is suitable for the most recent non-linear and computer loads, called capacitive loads, with a leading PF close to 0.9 and a high crest factor. Output voltage adjustable to 3% of the rated value (in 0.5 V steps) to take into account voltage drops in long cables. Excellent response to load step changes, < 2% for 100 to 0% or 0 to 100% and return to the 1% tolerances within 100 ms. High current-limiting capacity for inverter short-circuits (2.5 In, 150 ms) to facilitate discrimination with downstream protective devices and accept high crest factors, 2.4:1 up to 3:1, depending on the voltage and power levels. Intelligent thermal-overload capacity curve for better performance. The curve is adjusted as a function of the ambient temperature, 1.5 In / 30 seconds, 1.25 In / 10 minutes. Time in seconds Fig. 38. Inverter thermal-overload capacity curve. An energy-efficient range for energy savings TM TM Through its innovations, MGE Galaxy 7000 also enhances efficient energy use. IGBT-based, PFC charger drawing sinusoidal current. Inverter without an output transformer, with a reconstituted neutral. This new feature, made possible for high power levels by the progress in IGBTs and their drop in price, has resulted in: - reduced footprint - reduced weight - better efficiency - output-voltage regulation based on free-frequency modulation, enabling better adaptation to loads. Exceptional efficiency of 94.5%, virtually constant from 25 to 100% load, and 97% in ECO mode, resulting in significant savings on the energy bill and in sizing airconditioning and ventilation systems. Efficiency (%) 94.5 100 94.5 94.5 Load (%) 0 25 50 75 100 Fig. 39. Efficiency of a 300 kVA UPS. Rapid battery recharging is standard (e.g. 6 hours for 10 minutes of backup time), thus contributing to energy savings. Charger operation protects the battery because micro-outages up to 3 ms do not call on battery power. APC by Schneider Electric 05/2009 edition ch. 4 - p.35 MGETM GalaxyTM 7000 UPS (cont.) Power rating increased by 7.5% for ambient temperatures below 20°C. For example, below 20°C, 322 kVA may be drawn from a 300 kVA MGETM GalaxyTM 7000. Power uprating / derating coefficient 1.075 1.075 at 20°C 1.050 1.025 1 at 35°C 1.000 Slope 5% / 10°C 0.975 0.950 0.925 0.900 5 15 25 35 45 Ambient temperature (°C) Fig. 40. Power rating as a function of temperature. Effective, redundant and monitored ventilation - Ventilation by axial fans optimises component operation. - Each component is cooled by a redundant system of at least two fans. If one fails, the component continues to operate normally. - All fans are monitored (by a thermostat, sensor or NTC resistor) and an alarm is issued if a fault is detected. - Component life is calculated for an average temperature of 25°C. For temperatures higher than 40°C (adjustable parameter), the Ambient-temperature fault message is displayed. Inverter Chopper PFC Fig. 41. Redundant ventilation. The best, upgradeable architectures for each need There are many reasons to upgrade sites, including higher power needs, new types of loads requiring protection, changes in the electrical-distribution system, etc. Due to its very flexible modular design, MGETM GalaxyTM 7000 can handle each step in upgrade procedures without interrupting operations. High-availability architectures with two parallel configurations, integrated or with a centralised static-switch cabinet (SSC), to enhance availability and allow upgrades in step with the evolution of the overall installation. Compatibility with STS systems facilitates operation (redundant sources, redundant distribution lines) and enhances availability. Higher power rating through parallel connection of up to eight units Alarm signalling loss of redundancy, based on current for greater accuracy and better reliability. APC by Schneider Electric 05/2009 edition ch. 4 - p.36 MGETM GalaxyTM 7000 UPS (cont.) Advanced management to extend battery life MGETM GalaxyTM 7000 proposes backup times from 5 minutes to 2 hours with a rapid charger (recharge < 6 hours for 10-minute backup time). Backup time remains available due to digital battery management and the protection systems. The standard MGETM DigiBatTM system monitors the battery to forward information and maximise performance. Based on a large number of parameters (percent load, temperature, battery type and age), DigiBat controls the battery charge voltage and continuously calculates: - the real available backup time - the remaining battery life (1). DigiBat also offers: - automatic entry of battery parameters (1) - test on battery status to preventively detect operating faults - automatic battery discharge test at adjustable time intervals - protection against deep discharge taking into account the discharge rate, with a circuit breaker to isolate the battery. The breaker opens automatically after double the specified backup time plus two hours (sleep mode to provide vital functions) - limiting of the battery charge current (0.05 C10 to 0.1 C10) - gradual alarm signalling the end of backup time - numerous automatic tests. (1) Exclusive APC by Schneider Electric patents. Voltage Backup time Current DigiBat Percent load TM Calculation software Temperature Battery shutdown warning Service life Battery parameters Fig. 42. MGE TM DigiBat TM The B1000 battery monitoring or "Cellwatch" option monitors all battery strings 24/365 and displays a failure prediction for each block. User-friendly interface for more dependable operation MGETM GalaxyTM 7000 has a control and display interface offering intuitive functions. Based on graphs and pictograms, the interface can be set up in 19 languages including Chinese, Korean, Thai, Indonesian, Turkish and Greek. It includes a graphical display for time-stamped events and useful operating statistics. For operating personnel, that is an essential aspect in facilitating decisions. Simple and user-friendly, the interface enhances safety and comfort. Graphical display with HD, B&W touch screen (SVGA). Animated mimic panel. Menu keys and direct access to display functions. Buzzer. Remote supervision that can run under many BMS systems and network supervisors via the communication cards. Time-stamping of last 2500 events. On-line help to assist with the displayed messages. Multi-mode for parallel units (integrated parallel UPSs, parallel UPSs with SSC, frequency converters in parallel), i.e. it is possible to read the measurements of any unit on any unit, or to read system data. Operating LEDs (load protected, minor fault, major fault) Help key Function keys Menu key Mimic panel ON and OFF buttons Fig. 43. HMI with display, LEDs, keys and mimic panel. APC by Schneider Electric 05/2009 edition ch. 4 - p.37 MGETM GalaxyTM 7000 UPS (cont.) Advanced communication MGETM GalaxyTM 7000 is compatible with the APC by Schneider Electric range of communication solutions designed to meet three essential needs. Inform on UPS operation and its environment, warn users, wherever they may be, concerning any potential and existing problems. Protect server data by automatic, controlled shutdown of operating systems Actively supervise an entire set of UPSs. These functions are carried out by hot-pluggable communication cards running under different protocols, depending on the environment in which MGETM GalaxyTM 7000 is installed. Standard relay card with programmable dry contacts (4 logic inputs and 6 logic outputs). INMC (Industrial Network Management Card) communication card with two ports: - JBus/ModBus RS485/RS232 protocol for communication with a BMS - Ethernet 10/100 Mbps protocol using the Https standard (secure connection) for supervision via the web. Each UPS then has its own IP address making it possible for the user to: - supervise and control the UPS via a simple browser (HTTP) - interface with an SNMP administration system (HP Openview, etc.) - communicate with shutdown software installed on the protected servers - set up external temperature and humidity monitoring (sensor environment) - receive e-mail alarms. NMTC (Network Management Teleservice Card) communication card with three ports: - JBus/ModBus RS232/RS485 - Ethernet 10/100 Mbps using the Https protocol. The functions are identical to the INMC card, with in addition: - a modem connection may be used to connect the UPS to the Teleservice centre. Life Cycle Monitoring software for optimised maintenance. Installation Compact modular design with total access through the front MGETM GalaxyTM 7000 uses the latest technical and mechanical advances in terms of electrical components and power electronics. The greatly reduced number of components offers: An overall solution that is very compact, but high accessible for maintenance Integration of many functions in a single cabinet. The batteries, installed in a separate cabinet, can be hot-swapped (with the UPS supplying the load). Fig. 44. Compact modular design with total access through the front. The UPS can be installed in both technical and computer rooms. The UPS can operate correctly back to the wall or back to back, but it is preferable to leave some space (> 600 mm) for easier maintenance. Leave one meter of free space in front of the UPS for door opening. At least 500 mm of clearance above the UPS is required. Standard accessories for IP32 degree of protection. APC by Schneider Electric 05/2009 edition ch. 4 - p.38 MGETM GalaxyTM 7000 UPS (cont.) Fig. 45. Installation and IP32 accessories. Types of cabinets Parallel connection Rating H x W x D (mm) UPS cabinets 250 kVA 1900 x 1412 x 855 300 kVA 1900 x 1412 x 855 400 kVA 1900 x 1412 x 855 500 kVA 1900 x 1812 x 1812 External-bypass cabinets 800 kVA 1900 x 1012 x 855 1200 kVA 1900 x 1412 x 855 2000 kVA 1900 x 1412 x 855 SSC cabinets 800 kVA 1900 x 1012 x 855 1200 kVA 1900 x 1412 x 855 2000 kVA 1900 x 2424 x 855 Max. weight (kg) Width Battery / auxiliary cabinets 400 mm 1900 x 412 x 855 700 mm 1900 x 712 x 855 1000 mm 1900 x 1012 x 855 1400 mm 1900 x 1412 x 855 Max. weight empty (kg) 960 960 1110 1470 320 665 1700 425 720 2200 100 135 150 200 Integrated parallel and parallel UPSs MGETM GalaxyTM 7000 offers integrated parallel UPS units with internal automatic and manual bypasses (figure 46a) and parallel UPS units without internal bypasses, (figure 46b) that can be connected in parallel to increase available power and/or provide redundancy. Normal AC input Battery Bypass AC input PFC rectifier PFC rectifier CB Charger Static switch Maintenance Bypass CB Charger Inverter Inverter Load Fig. 46a. Integrated parallel UPS unit APC by Schneider Electric Normal AC input Battery 05/2009 edition Load Fig. 46b. Parallel UPS unit ch. 4 - p.39 MGETM GalaxyTM 7000 UPS (cont.) Parallel connection uses a CAN bus with a maximum length of 200 metres. ECO mode is not possible in a parallel configuration. When the parallel configuration includes a redundant unit, an alarm signals loss of redundancy. Parallel connection must satisfy minimum cable lengths to avoid excessive exchange currents in the UPS output capacitors. For n integrated parallel UPS units (Fig. 46, 47 and 48), the cables connecting the UPS outputs must have a total length of at least n x 6 m. In addition, the cables connecting each bypass AC input to the upstream bypass source should all be of the same length. 2 integrated parallel UPSs for redundancy Two integrated parallel units may be connected in parallel (without an external bypass) for redundancy. The second unit may be added without interrupting operation. The UPS units share the load and each has a bypass. Given that this configuration includes only 2 units, it is not necessary to have an external bypass. If one UPS unit stops, the other continues to supply the full load. Redundancy makes it possible to carry out maintenance on one of the units. Battery Normal AC input Bypass AC input Battery Normal AC input Bypass AC input L1 L2 Load Cable lengths L1 + L2 2 x 6 = 12 m Fig. 47. 2 integrated parallel UPS units in parallel for redundancy. Integrated parallel UPSs in parallel with an external bypass Up to eight integrated parallel units can be connected in parallel with an external bypass for increased power and/or redundancy. Units may be added without interrupting operation. The external bypass serves for all units and is sized for the maximum load. The internal bypasses of each integrated parallel unit are not used and are locked in open position. With redundancy: - if one UPS unit stops, the others continue to supply the full load - it possible to carry out maintenance on one of the units. Without redundancy: - if one UPS unit stops, all units go to the bypass AC inputs which share the load - maintenance on a unit does not require installation shutdown. The unit in question goes to downgraded mode after flipping the necessary switches. APC by Schneider Electric 05/2009 edition ch. 4 - p.40 MGETM GalaxyTM 7000 UPS (cont.) Bypass AC input Battery Normal AC input Battery Normal AC input Battery L2 L1 Normal AC input L3 External maintenance bypass Load Cable lengths L1 + L2 + L3 3 x 6 = 18 m Fig. 48. Integrated parallel UPSs in parallel with an external bypass. Parallel UPSs with static switch cabinet (SSC) Up to eight parallel units (without internal bypasses) can be connected in parallel with an SSC for increased power and/or redundancy Another unit may be added without interrupting operation. The SSC serves for all units. Its static switch and bypass are sized for the maximum load. With redundancy: - if one UPS unit stops, the others continue to supply the full load - maintenance on all units is possible simply by transferring to the SSC Without redundancy: - if one UPS unit stops, all units transfer to the SSC - maintenance on one or all units is possible simply by transferring to the SSC. Maintenance on the SSC and its static switch is possible. Advantages of this configuration compared to the previous configurations: - enhanced availability - easier maintenance, due to the centralised bypass - greater short-circuit withstand capability. Battery Nomal AC input L1 Normal AC input Battery L2 Normal AC input Bypass AC input L3 Centralised static-switch cabinet Load Cable lengths L1 + L2 + L3 3 x 6 = 18 m Fig. 49. Parallel UPSs with static switch cabinet (SSC). APC by Schneider Electric 05/2009 edition ch. 4 - p.41 MGETM GalaxyTM 7000 UPS (cont.) Parallel connection of UPSs with STS units MGETM GalaxyTM 7000 can also be used in parallel UPS configurations with synchronisation and STS (Static Transfer System) units. Source 1 Normal Source 2 Bypass Normal Bypass ASI ASI Synchro STS 1 Load 1 STS 2 Load 2 Fig. 50. Parallel connection with STS units. APC by Schneider Electric 05/2009 edition ch. 4 - p.42 MGETM GalaxyTM 7000 UPS (cont.) Equipment and diagrams MGETM GalaxyTM 7000 UPS units offer the following equipment and functions. Standard Normal Bypass ● IGBT-based, PFC three-phase rectifier AC input AC input ● Phase-sequence check on input ● Chopper for battery charging, insulated from Battery AC input, charge adjusted for ambient UPS temperature Q1 Q4S ● Static switch (except parallel UPS units) Rectifier ● Manual bypass (except parallel UPS units) QF1 ● Three-phase IGBT inverter with freeCharger Q3BP frequency PWM chopping ● Redundant ventilation for power components SS ● HMI with graphical interface, 19 languages, Inverter menu, function and ON/OFF keys ● Mimic panel with status LEDs ● Time-stamping of last 2500 events Q5N ● Battery protected against deep discharges by a circuit breaker ● Cold start on battery power ● Soft start with walk-in ramp and sequential Load start in parallel configurations Fig. 51. Single UPS. ● DigiBat digital battery monitoring and calculation of real backup time ● Programmable relay card, 4 logic inputs, 6 logic outputs Options ● Connection through the top ● Isolation/voltage matching transformer ● Synchronisation module ● B2000 or Cellwatch battery-monitoring system for block by block management ● Lightning arrestor (built into the UPS cabinet) ● Backfeed protection ● Multi-standard communication cards: - Jbus/Modbus + Ethernet 10/100 - Jbus/Modbus + Ethernet 10/100 + Modem - 2 ports with dry contacts and/or remote shutdown ● Battery circuit breaker unit ● Supervision and shutdown software: - Enterprise Power Manager MGETM GalaxyTM 7000 centralised static switch cabinets offer the following equipment and functions. Bypass Standard AC input ● Designed for parallel connection of up to 8 parallel UPS units ● Centralised static switch cabinet sized for Static the power of the installation Switch Q4S Cabinet ● All the necessary switches for automatic and maintenance bypass functions Q3BP ● Connection possible from the bottom or the top ● Centralised graphic display and monitoring ● Current-based alarm signalling loss of redundancy UPS Q5N Optional ● Synchronisation module ● Connection through the top Load Fig. 52. Static switch cabinet. APC by Schneider Electric 05/2009 edition ch. 4 - p.43 MGETM GalaxyTM 7000 UPS (cont.) Electrical characteristics Power rating Pn (kVA) 250 300 400 (rated output apparent power) Active power for PF = 0.9 (kW) 225 270 360 Electrical input characteristics (rated values and tolerances) Number of phases 3 ph (1) Voltage Normal AC input at Pn: 380 V / 400 V / 415 V ± 10% at 30% Pn: 250 V (1) Bypass AC input 380 V / 400 V / 415 V ± 10% Frequency Utility 50 or 60 Hz ± 10%, i.e. 45 to 65 Hz Power factor 50 to 100% load 0.99 (2) Current total harmonic distortion THDI < 5% Current See table on input currents Phase sequence Device to check the phase sequence (correct connection) Electrical output characteristics (rated values and tolerances) Number of phases 3Ph + N Rated voltage 380 / 400 / 415 V ± 1% three-phase at 50 Hz (rated rms output 380 / 400 ± 1% three-phase at 60 Hz Fine adjustment possible via human-machine interface to Un ± 3% value) Frequency AC power sync 50 or 60 Hz ± 0.5 Hz (adjustable) Free running ± 0.02 Hz Power factor 0.9 Voltage distortion Linear load 2% ph/ph or ph/N (3) THDU 500 450 (4) Inverter short-circuit capacity 2.5 to 3 x In for 150 ms 400 V : 3 In for 250 kVA, 2.5 In for 300 and 400 kVA , 2.75 In for 500 kVA Inverter overload capacity 125% for 10 minutes - 135% for 1 minute - 150% for 30 seconds (4) Static-switch overload capacity Ipeak / In for 20 ms – values below Single or integrated Up to 25 In (16 In for 400 and 500 kVA - 21 In for 300 kVA, 25 In for 250 kVA) parallel UPS unit Crest factor at Up to 3:1 380 / 400 / 415 V Dynamic performance: voltage variation for ± 2% for load step changes from 0 to 100% and 100 to 0% load step changes Recovery time (return to ± 1% tolerance) < 100 ms Voltage and phase imbalance 1.5% and 2 degrees for 50% current imbalance Maximum frequency variation 1 Hz/s or 2 Hz/s (adjustable) Efficiency Double-conversion 50 to 100% Up to 94.5% (97% in ECO mode) mode Conditions for transfer without interruption between normal and bypass lines (synchronisation with bypass source) Bypass-source voltage tolerances Un ± 10% Bypass-source frequency tolerances 50 or 60 Hz ± 0.5 to 8% of rated frequency, adjustable to 0.5 - 1 - 2 - 4 - 8% Phase-difference tolerances 3 degrees Transfer with interruption If any parameters are outside tolerances, transfer can be carried out with an adjustable (bypass source outside tolerances) interruption of 13 to 100 ms, after authorisation by the user via the operator keypad Battery Type Sealed lead-acid or optional vented lead-acid or nickel-cadmium Service life Up to 10 years or more Backup time 5 - 10 - 15 - 20 - 30 minutes standard (5) Charge time 5 minutes 4 hours 4 hours 4 hours 4 hours depending on backup 10 minutes 6 hours 5 hours 6 hours 6 hours time 15 minutes 6 hours 7 hours 7 hours 7 hours 20 minutes 7 hours 7 hours 6 hours 7 hours 30 minutes 8 hours 8 hours 9 hours 9 hours (1) Other voltages on request 208, 220, 480 V. (2) THDI (Total Harmonic Distortion of current). (3) THDU (Total Harmonic Distortion of voltage). (4) In = rms output current (PF = 0.9), i.e. In Pn 0.9 Un 3 (5) Recharge following complete discharge at Pn, to 90 % of total charge and 80 % of total backup time. APC by Schneider Electric 05/2009 edition ch. 4 - p.44 MGETM GalaxyTM 7000 UPS (cont.) Communication Power rating Pn (kVA) (rated output apparent power) Active power for PF = 0.9 (kW) HMI (Human-machine interface) Standard Communication Standard Options Software Standard Options 250 300 400 500 225 270 360 450 Operating LEDs (load protected, minor fault, major fault) N&B graphical display, SVGA (800 x 600 pixels), 32 cm Help key Function keys Menu key ON and OFF buttons Mimic panel with status LEDs Programmable relay card, dry contacts, 4 logic inputs, 6 logic outputs Multi-standard communications card with two or three outputs: - INMC with 2 outputs: JBus/Modbus/RS232/RS485 + Ethernet 100/100 bps - NMTC with 3 outputs: JBus/Modbus/RS232/RS485 + Ethernet 100/100 bps + Modem - 2 ports with dry contacts and/or remote shutdown Solution Pac (parameter setting by trained and qualified personnel) Enterprise Power Manager V2 Physical characteristics - dimensions and weight Power rating Pn (kVA) (rated output apparent power) Active power for PF = 0.9 (kW) UPS cabinet without battery 250 300 400 500 225 270 360 450 H (mm) 1900 W (mm) 1412 D (mm 855 Weight (kg) 960 960 1110 External-bypass cabinet for parallel connection of up to eight units Height H = 1900 mm Depth D = 855 mm Rating Width (mm) / Weight (kg) 800 kVA 1012 / 320 1200 kVA 1412 / 665 2000 kVA 1412 / 1700 Please consult us 3200 kVA Please consult us 4800 kVA Static-switch cabinet with automatic and manual bypass for parallel connection of up to eight units Height H = 1900 mm Depth D = 855 mm Rating Width (mm) / Weight (kg) 800 kVA 412 / 425 1200 kVA 1412 / 720 2000 kVA 2424 / 2200 Please consult us 3200 kVA Please consult us 4800 kVA APC by Schneider Electric 05/2009 edition 1812 1470 ch. 4 - p.45 MGETM GalaxyTM 7000 UPS (cont.) Physical characteristics - environment and standards Power rating Pn (kVA) (rated output apparent power) Active power for PF = 0.9 (kW) Environment Colour of cabinets Degree of protection (as per IEC 60529) Noise level (dBA) ISO 3476 Heat losses (kW) UPS 250 300 400 500 225 270 360 450 RAL 9023 IP20 and IP32 version 72 7 8.6 11.2 14.3 14.3 22.9 27.2 50% load UPS 17.2 100% load 3 Fan throughput Maximum altitude m /h Without derating With derating Storage temperature Without battery range With battery Operating temperature Inverter range Battery Humidity Standards Construction and safety EMC Harmonics Design, manufacturing Certification and marking APC by Schneider Electric 6000 8300 1000 m 0.85 at 1500 m - 0.79 at 2000 m - 0.75 at 2300 m - 0.69 at 3000 - 0.59 at 4000 m - 25°C to + 70°C dry heat - 10°C to + 45°C Steady-state conditions: 35°C 8 hours max.: 40°C 20°C to 25°C recommended for optimum battery operation tolerable: 0 to 35°C (40°C for 8 hours) optimum: + 15°C to + 25°C (service life cut in half for every 10°C increase above 25°C) 20% to 95% without condensation at ambient temperature IEC 60950-1 IEC 62040-1 IEC 62040-3 EN 50091-2 IEC 62040-2 / EN 62040-2 EMC directive 2004/108/EC IEC 61000-2-2 / EN 61000-2-2 IEC 61000-3-2/ EN 61000-3-2 IEC 61000-3-4 EN 61000-3-4 IEC 61000-3-5 EN 61000-3-5 ISO 14001 / ISO 9001 TÜV / CE / LCIE 05/2009 edition ch. 4 - p.46 MGETM GalaxyTM 7000 UPS (cont.) Current characteristics for selection of protection devices Power rating Pn (kVA) (rated output apparent power) Active power for PF = 0.9 (kW) Input currents 250 300 400 500 225 270 360 450 Currents and measurement conditions ● I1: current at normal AC input Currents and measurement conditions ● Iu: load current N.B. Currents are measured at: ● full rated load, PF = 0.9 ● rated voltage 400 V of normal AC source ● battery float charging. For normal AC-source rated voltages of 380 and 415 V, multiply the I1 and Iu values by 1.05 and 0.96 respectively. ● Ibmax: maximum battery current Max. input current I1 (A) Fig 53. Input currents. 351 420 558 700 Load current Iu (A) Max. current supplied by battery Ibmax (A) 361 490 577 784 722 980 APC by Schneider Electric 433 588 05/2009 edition ch. 4 - p.47 MGETM GalaxyTM 9000 UPSs Presentation Protection for your mission-critical high-power applications up to several MVA Fig. 4.54. MGE TM TM Galaxy MGETM GalaxyTM 9000 ● Power ratings: 800 - 900 kVA ● Three-phase input and output ● Parallel connection of up to six UPS units, e.g. 6 x 800 kVA = 4.8 MVA ● On-line double conversion (VFI) ● Automatic and manual bypasses ● Total control over upstream harmonics by filtering (THDI < 4%) ● IGBT technology ● Backup times from 5 min. to 4 hours or more with a rapid charger for more secure operation (recharge < 11 hours) ● Wide input-voltage range from 323 to 456 V to handle disturbed distribution systems ● High overload and discrimination capacity ● Input-current limiting during genset start ● Highest efficiency in its category with 94% in double-conversion mode, even at low percent loads ● Graphic, colour UMI with "Vision" option for supervision of all modules ● Digital battery management by DigiBatTM (calculation of real backup time and remaining battery life) and block by block monitoring ● Low TCO due to an optimised environment (cables, protection, genset compatibility), small footprint, high efficiency and monitoring of multiple UPS units using Enterprise Power Manager software. 9000 range. Applications MGETM GalaxyTM 9000 is part of the high-power range of 3-phase UPSs from APC by Schneider Electric, offering 800 to 900 kVA UPS units and parallel configurations up to 5.4 MVA. Based on the proven technological solutions of the Galaxy ranges (modular design, double conversion, IGBTs), it combines power, high availability and upgradeability to offer custom solutions ... as standard! Data centres - The possibility of flexible no-risk upgrading is essential for strategic data centres. These installations generally represent a few hundred kVA initially, but often grow to reach several MVA. The different parallel-connection modes available for MGETM GalaxyTM 9000 perfectly match these needs. Combined with STS units, the UPS can supply energy via two or three different channels for dual or triple-attach applications. It also offers a number of solutions for supervision, network administration and remote control. Telecommunications - A telecom installation must operate 24/365. Operations TM must continue during preventive maintenance and installation upgrades. MGE TM Galaxy 9000 meets these needs through a high level of availability (redundant, parallel configurations, high-power charger for fast recharging, etc.) and communication for proactive maintenance (EPM supervision software for multiple UPS units, built-in communication cards, connection to internet). APC by Schneider Electric 05/2009 edition ch. 4 - p.48 MGETM GalaxyTM 9000 UPSs (cont.) Industrial processes - Operation in industrial environments requires equipment capable of maintaining processes, without failure, under difficult conditions, including dust, humidity, vibrations, major variations in temperature, etc. Due to its wide TM TM catalogue of options and functions, MGE Galaxy 9000 can adapt to all types of environments. Technical files are available for all the applications specified by design offices, including Ni-Cad batteries for the chemical and petrochemical industries, high IP values, heavy-duty reinforced cabinets, dust filters, marine configurations, rated voltages up to 440 V, etc. The APC by Schneider Electric design office, in conjunction with a specialised industrial organisation, can also handle uncommon conditions, e.g. outdoor installations, anti-vibration bases for marine applications, special paints with the corresponding labels, etc. Colour Light grey RAL 9023. Main advantages High-availability power solutions tailored to high-power missioncritical installations APC by Schneider Electric has equipped the high-power MGETM GalaxyTM 9000 range with all the functions and options required to provide high-quality energy 24/365 in all environments and for all applications. Optimum reliability thanks to modular design, proven technology and a reduced number of components. Double conversion (VFI as per IEC 62040-3/EN 62040-3), with built-in automatic and manual bypass lines. This design completely regenerates the current and provides the highest quality output voltage and frequency, with a THDU < 4% for all types of loads. Discrimination due to high short-circuit capacity and a high permissible crest factor. Backup time remains available due to digital battery management: TM TM - The MGE DigiBat system monitors the battery to forward information and maximise performance. Based on a large number of parameters (percent load, temperature, battery type and age), Digibat controls the battery charge voltage and continuously calculates the real available backup time and the remaining service life - MGETM GalaxyTM 9000 can be equipped with the B2000 or Cellwatch batterymonitoring systems that monitor each battery string around the clock and predict the risk of failure block by block. High-availability architectures with two parallel configurations, integrated parallel or parallel with a centralised static-switch cubicle, to enhance availability and make possible upgrades in step with the overall installation. Possibility of synchronisation with all types of sources to supply downstream STSs (static transfer switches) and ensure maximum availability for the protected loads. Total compatibility with gensets due to the following special features: - no harmonic currents drawn and high power factor using proven filtering solutions - rectifier/charger walk-in to facilitate genset start - battery charge-current limiting during operation on genset power - sequential start of UPS units (parallel configuration). Fig. 4.55. Walk-in ramp with time delay. APC by Schneider Electric 05/2009 edition ch. 4 - p.49 MGETM GalaxyTM 9000 UPSs (cont.) Continuity of service is the priority There are many reasons to upgrade sites, including higher power needs, new types of loads requiring protection, changes in the electrical-distribution system, etc. Due to its very flexible modular design, MGETM GalaxyTM 9000 can handle each step in upgrade procedures without interrupting operations. The number of available architectures facilitates operation (redundant sources, redundant distribution lines) and enhances availability. Parallel connection can be used to multiply the available power by a factor of up to six. Easy, safe maintenance on the electrical installation, due to the wide range of configurations (modular, with common centralised bypass, etc.). Large selection of batteries (sealed or vented lead-acid, Ni/Cad) and backup times. Coldstart function - the UPS can start on battery power. A "clean" UPS For single or parallel configurations, integrated filtering solutions eliminate upstream harmonics problems and ensure trouble-free operation without disturbing the upstream power system: THDI < 4% (total distortion of the input current) PF > 0.95 (input power factor) Other upstream filtering solutions are available (LC compensated or noncompensated filters designed for installations supplied by generator sets). For configurations with three or more UPS units in parallel, phase-shifting is the most cost-effective solution, offering excellent performance and easy installation at a very competitive price. Optimum output voltage quality and outstanding efficiency Galaxy UPSs use IGBT technology, reducing the number of components and thereby improving reliability. The operation of the IGBTs has been optimised using an exclusive free-frequency chopping mode combined with PWM type regulation to offer unmatched performance: Output voltage quality: - Very low level of distortion, 3 % ph/ph, 4 % ph/N (RCD loads as per ENV 50091-3) Steady-state accuracy: ± 0.5% of rms values of phase-to-neutral and phase-tophase voltages. Settings: Via the UMI, the output voltage can be fine-tuned within the Un ± 3% range, making it possible to take into account voltage drops due to long cables downstream of the UPS. Transient performance: ± 5 % for load step changes from 100% to 0 and 0 to 100% (i.e. loads turned on or off). The return to the ± 1% range (rms values) takes place in less than 20 ms. Outstanding efficiency of up to 94 %, virtually constant from 25% to 100% load. This means significant savings on the energy bill and in sizing air-conditioning and ventilation systems. Free-frequency switching Quality band with variations < 1% Output voltage curve Up to 8 commutations per millisecond The regulation system continuously compares the output voltage with a reference wave generated by an internal processor. Free-frequency switching accelerates (higher frequency) during periods of major variations for better regulation. Fig. 4.56. Free-frequency switching. APC by Schneider Electric 05/2009 edition Fig. 4.57. Efficiency of a 800 kVA MGE TM Galaxy 9000 UPS unit. TM ch. 4 - p.50 MGETM GalaxyTM 9000 UPSs (cont.) User-friendly interface for more dependable operation MGETM GalaxyTM 9000 has the new "Vision" communication interface offering intuitive functions. Entirely new, based on graphics and pictograms, "Vision" presents a wide range of UPS operating status information, time-stamped events and valuable statistics. For operating personnel, that is an essential aspect in facilitating decisions. Simple and user-friendly, the interface enhances safety and comfort: wide touch screen, colour, high resolution (SVGA) with animated mimic panel remote supervision that can run under many BMS systems and network supervisors time-stamping of last 3000 events. Advanced communication MGETM GalaxyTM 9000 is compatible with the APC by Schneider Electric range of communication solutions designed to meet three essential needs: Inform on UPS operation and its environment, with the possibility of warning users wherever they may be of all potential and existing problems Protect server data by automatic, controlled shutdown of operating systems Actively supervise an entire set of UPSs. These functions are carried out by hot pluggable communication cards using different protocols, depending on the environment in which the UPS is installed. Standard relay card with programmable dry contacts (4 logic inputs and 6 logic outputs). INMC (Industrial Network Management Card) communication card with two ports: - JBus/ModBus RS485/RS232 protocol for communication with a BMS - Ethernet 10/100 Mbps protocol using the Https standard (secure connection) for supervision via the web. Each UPS then has its own IP address making it possible for the user to: - supervise and control the UPS via a simple browser (HTTP) - interface with an SNMP administration system (HP Openview, etc.) - communicate with shutdown software installed on the protected servers - set up external temperature and humidity monitoring (sensor environment) - receive e-mail alarms. NMTC (Network Management Teleservice Card) communication card with three ports: - JBus/ModBus RS232/RS485 - Ethernet 10/100 Mbps using the Https protocol. The functions are identical to the INMC card, with in addition: - a modem connection may be used to connect the UPS to the Teleservice centre. Fig. 4.58. Example of a MGE APC by Schneider Electric 05/2009 edition TM TM Galaxy 9000 supervision screen ch. 4 - p.51 MGETM GalaxyTM 9000 UPSs (cont.) Reduction in costs (TCO) The high level of availability protects against operating losses, but at a cost in terms of protection-system investment and installation expenses as well as the operating costs. TCO analysis attempts to determine the best return on the investment. Two main criteria contribute to reducing MGETM GalaxyTM 9000 installation and operating costs: compact size and installation with the back to the wall make for a small footprint and definite savings in terms of square metres high efficiency (up to 94%) means savings on the energy bill and when sizing airconditioning and ventilation systems. Installation Parallel connection The UPS can be installed in both technical and computer rooms. The UPS can operate correctly back to the wall or back to back, but it is preferable to leave some space (> 600 mm) for easier maintenance. Leave one meter of free space in front of the UPS for door opening. At least 250 mm of clearance above the UPS is required. The design of MGETM GalaxyTM 9000 enables parallel connection of units with identical ratings in order to increase the available power or provide redundancy. It is also possible to use a centralized bypass comprising the automatic bypass and the manual bypass for all UPS units. Parallel connection of two standard UPS units for active redundancy In this case, parallel connection of a second unit is intended to increase the availability of energy. Two identical UPS units, each with its built-in manual bypass, supply the load at the same time in parallel (hence the term active redundancy). However, each unit can supply the load alone if the other is stopped. This type of redundancy is called 1/2. The second unit can be connected in parallel without interrupting the load. Connection is possible with separate or common normal and bypass AC inputs. Normal AC input Module 1 (a) Bypass AC input Normal AC input Normal AC input Bypass AC input Module 2 Module 1 Load (b) Bypass AC input Normal AC input Bypass AC input Module 2 Load Fig. 4.59. Active redundancy with parallel connection of two standard units, with separate (a) or common (b) normal and bypass AC inputs. APC by Schneider Electric 05/2009 edition ch. 4 - p.52 MGETM GalaxyTM 9000 UPSs (cont.) Parallel connection of 3 to 6 UPS units for power and/or redundancy MGETM GalaxyTM 9000 also allows parallel connection of 3 to 6 UPS units. Parallel connection ofup to 4 integrated parallel UPS units. Each integrated parallel unit includes a static bypass, with a common external maintenance bypass unit sized for the maximum power. The UPS units share the load to be supplied. Depending on the level of active redundancy, if one or more UPS units stop, the others continue to supply the load. Bypass AC input EXTERNAL BYPASS UNIT Normal AC input Normal AC input UPS1 Normal AC input UPS2 P1(kVA) UPS3 P1(kVA) P1(kVA) Load Fig. 4.60. Three integrated parallel units with an external bypass unit. Parallel connection of up to 6 parallel UPS units without internal bypasses. This configuration requires a common static switch cubicle (SSC) and a common external maintenance bypass unit sized for the maximum power. The parallel UPS units have no internal bypass and share the load to be supplied. Depending on the level of active redundancy, if one or more UPS units stop, the others continue to supply the load. Compared to parallel configurations with automatic bypasses in each unit and a common external bypass, this solution offers the following advantages: - Enhanced availability - Easier maintenance, due to the centralized bypass - Greater short-circuit withstand capability. Normal AC input Parallel UPS unit 1 Normal AC input Parallel UPS unit 2 Normal AC input Parallel UPS unit 3 Static Switch Cubicle (SSC) Bypass AC input Load Fig. 4.61. Parallel connection with a centralized bypass. APC by Schneider Electric 05/2009 edition ch. 4 - p.53 MGETM GalaxyTM 9000 UPSs (cont.) Parallel connection of UPSs with STS units MGETM GalaxyTM 9000 can also be used in parallel UPS configurations with synchronisation and static transfer switches (STS). Source 1 Normal Source 2 Bypass Normal Bypass Synchro STS 1 Load 1 STS 2 Load 2 Fig. 4.62. Parallel connection with STS units. APC by Schneider Electric 05/2009 edition ch. 4 - p.54 MGETM GalaxyTM 9000 UPSs (cont.) Diagram and functions APC by Schneider Electric MGETM GalaxyTM 9000 single-UPS units offer the following equipment and functions. Standard ● Three-phase IGBT inverter with freefrequency PWM chopping ● Static switch ● Manual maintenance bypass ● Mimic panel with status LEDs. ● Time-stamping of last 3000 events ● Battery protected against deep discharges by a circuit breaker ● Parallel configurations with integrated parallel UPS units or centralised static switch cubicle ● EMC C3 monitored distribution ● Sequential start of UPS units (parallel configurations). ● DigiBat Battery Monitoring, with calculation of the true backup time ● Cold start on battery power ● Battery charging shutdown during operation on genset ● Rectifier walk-in and current limiting to ensure compatibility with gensets ● Battery charger adaptation to ambient Fig. 4.63. Single-UPS unit temperature of battery room ● Redundant ventilation for the static switch Optional: ● Active harmonic filtering ● Passive filters (non-compensated, with contactor or compensated) or phase shifting filters ● Connections from the top ● Isolation/voltage matching transformer ● Synchronisation module ● 12" SVGA colour graphic display ● B2000 or Cellwatch battery-monitoring system ● Lightning arrestor (built into the UPS cabinet). ● Backfeed protection ● EMC C2 class A. ● Communication cards: - JBus/ModBus RS232 or RS485 - SNMP / Ethernet - 2 ports with dry contacts and/or remote shutdown ● Battery circuit breaker unit ● Supervision and shutdown software: - Enterprise Power Manager V.2 05/2009 edition ch. 4 - p.55 MGETM GalaxyTM 9000 UPSs (cont.) MGETM GalaxyTM 9000 centralised static switch cubicles offer the following equipment and functions. Standard ● Centralised static switch cubicle sized for the power of the installation ● All the necessary switches for automatic and maintenance bypass functions ● Connection possible from the bottom or the top ● Centralised graphic display and monitoring ● Media Contact 9 communication port and JBus/Modbus ● Designed for parallel connection of up to 6 UPS units Optional ● Synchronisation module ● Connections from the top Fig. 4.64. Centralized static switch cubicle APC by Schneider Electric 05/2009 edition ch. 4 - p.56 MGETM GalaxyTM 9000 UPSs (cont.) Electrical characteristics Power rating Pn 800/900 (rated output apparent power) Active power (kW) 720/720 Electrical input characteristics (rated values and tolerances) Number of phases 3 (1) Voltage Normal AC input 380 V -15% to 415 V + 10% (1) Bypass AC input 380 V / 400 V / 415 V ± 10% Frequency Utility 50 or 60 Hz ± 10%, i.e. 45 to 65 Hz Power factor 75 to 100% 0.95 (with active filter) (2) Current total harmonic distortion THDI < 4% (with active filter) Current See table on input currents Electrical output characteristics (rated values and tolerances) Number of phases 3Ph + N Rated voltage 380 / 400 / 415 V ± 0.5% three-phase at 50 Hz (* rated rms output 380 / 400 ± 0.5% three-phase at 60 Hz value) Fine adjustment possible via user-machine interface to Un ± 3% Frequency AC power sync 50 or 60 Hz ± 0.5 Hz (adjustable) Free running ± 1/2500 = 0.0004 Hz Power factor 0.9 (for 800 kVA) / 0.8 (for 900 kVA) Voltage total harmonic Linear load 3% Ph/Ph, 4% Ph/N (3) distortion THDU (4) Short-circuit capacity of the inverter 2.33 In peak In for 1 s Overload capacity of the inverter 125% for 10 minutes - 150% for 1 minute (4) Overload capacity of bypass (SS) I peak / In for 20 ms - see values below Single UPS 19 In peak (for 800 kVA) / 17 In peak (for 900 kVA) Permissible crest factor Up to 3 : 1 Dynamic performance: voltage transients ± 5% for 0 to 100% or 100 to 0% load step changes during load step changes recovery time (return to ± 1%) < 20 ms Voltage and phase imbalance 1.5% and 2 degrees for 50% current imbalance Maximum frequency variation 1 Hz/s or 2 Hz/s (adjustable) Efficiency Double-conversion 50 to 100% Up to 94% mode Conditions for transfer without interruption between normal and bypass lines (synchronisation with bypass source) Bypass-source voltage tolerances Un ± 10% Bypass-source frequency tolerances 50 or 60 Hz ± 0.25 to 2 Hz, adjustable in 0.5 Hz steps Phase-difference tolerances 3 degrees Transfer with interruption If any parameters are outside tolerances, transfer can be carried out with an adjustable (bypass source outside tolerances) interruption of 500 to 800 ms, after authorisation by the user via the operator keypad. Battery Type Sealed lead-acid or optional vented lead-acid or nickel-cadmium Service life Up to 10 years or more Backup time 5 - 10 - 15 - 30 minutes (standard) (1) Other voltages on request. (2) THDI (Total Harmonic Distortion for current). (3) THDU (Total Harmonic Distortion for voltage). (4) In = rms output current (PF = 0.8), i.e. APC by Schneider Electric In = Pn 0.8 Un 3 05/2009 edition ch. 4 - p.57 MGETM GalaxyTM 9000 UPSs (cont.) Communication Power rating Pn (rated output apparent power) Active power (kW) UMI (User-machine interface) Standard Options Communication Standard Options Software Standard Options 800/900 720/720 Operating LEDs (load protected, minor fault, major fault) On and Off buttons Help key Function keys Menu key Mimic panel with status LEDs Colour graphical display - SVGA (800 x 600 pixels) - 12’’ (32 cm) 1 relay card with dry contacts, 2 inputs and 6 outpus, 250V, 2A Communication cards: - RS232 - JBus/ModBus RS232 or RS485 - SNMP / Ethernet - 2 ports with dry contacts and/or remote shutdown Solution Pac (parameter setting by trained and qualified personnel) Enterprise Power Manager V2 Physical characteristics - dimensions and weight Power rating Pn 800/900 (rated output apparent power) Active power (kW) 720/720 UPS cabinet without battery H (mm) 2000 W (mm) 3600 D (mm) 840 Weight (kg) 4100 Combinations of battery cabinets for given backup times Height H = 2000 mm Depth D = 840 mm For height and weight for a given backup time, please consult us. External-bypass cabinet for parallel connection of up to four units Height H = 2000 mm Depth D = 840 mm Power Width (mm) / Weight (kg) 1200 kVA 1200 / 450 Centralized static switch cubicle with automatic and manual bypasses for parallel connection of up to six units Height H = 2000 mm Depth D = 840 mm Power Width (mm) / Weight (kg) 1200 kVA 1600 / 1000 2000 kVA 2450 / 1710 3200 kVA Please consult us 4800 kVA Please consult us APC by Schneider Electric 05/2009 edition ch. 4 - p.58 MGETM GalaxyTM 9000 UPSs (cont.) Physical characteristics - environment and standards Power rating Pn (rated output apparent power) Active power (kW) Environment Colour of cabinets Degree of protection (as per IEC 60529) Noise level (dBA) ISO 3476 Heat losses (kW) Single UPS 800/900 720/720 RAL 9023 IP20 < 72 48 (for 800 kVA) / 44 (for 900 kVA) 100% load Single UPS 33 (for 800 kVA) / 31 (for 900 kVA) 75% load Single UPS 22 (for 800 kVA) / 20 (for 900 kVA) 50% load 3 Fan throughput Maximum altitude m /h without derating with derating Storage temperature without battery range with battery Operating temperature inverter range battery Relative humidity Standards Construction and safety EMC Harmonics Design and manufacture Certification and marking 31000 1000 m 0.85 at 1500 m; 0.79 at 2000 m; 0.75 at 2300 m; 0.69 at 3000; 0.59 at 4000 m - 25°C to + 70°C dry heat - 10°C to + 45°C Full rated load, PF = 0.8: 0 to 35°C 30°C mean daily, 40°C for 8 hours once per month 20°C to 25°C recommended for optimum battery operation tolerable: 0 to 35°C (40°C for 8 hours) optimum: + 15°C to + 25°C (service life cut in half for every 10°C increase above 25°C) 45% to 75% without condensation at ambient temperature IEC 60950-1, IEC 62040-1, IEC 62040-3 EN 50091-2, IEC 62040-2 / EN 62040-2, EMC directive 2004/108/EC IEC 61000-2-2 / EN 61000-2-2, IEC 61000-3-2/ EN 61000-3-2, IEC 61000-3-4 EN 61000-3-4, IEC 61000-3-5 EN 61000-3-5 ISO14001 / ISO 9001 TüV / CE / LCIE Current characteristics for selection of protective devices Power rating Pn (rated output apparent power) Active power (kW) Input currents 800/900 720/720 Currents and measurement conditions ● I1: current at normal AC input Currents and measurement conditions ● Iu: load current N.B. Currents are measured at: ● full rated load, PF = 0.8 ● rated voltage of normal AC source is 400 V ● battery float charging. For normal AC-source rated voltages of 380 and 415 V, multiply the I1 and Iu values by 1.05 and 0.96 respectively. Max. input current I1 (A) for 15 minutes of backup time, battery recharging Load current Iu (A) Max. current supplied by battery Ibmax (A) APC by Schneider Electric ● Ibmax: maximum battery current Fig. 4.65. Input currents. 1329 1155 (for 800 kVA) / 1299 (for 900 kVA) 2274 05/2009 edition ch. 4 - p.59 SymmetraTM PX 48 and PX160 UPSs Presentation The right-sized scalable UPS for demanding businesscritical applications. SymmetraTM PX 48 and PX 160 ● Hot-scalable from 16 - 48 kW (PX 48) and 16-160 kW (PX 160) ● Three-phase input and output ● Fully modular design (power, intelligence, batteries, bypass and distribution) ● Hot scalable power, distribution & backup time by trained user ● Hot swappable internal bypass static switch ● High power density ● 95% efficiency down to 35% load ● Centralised management display ● On-line double conversion ● Input PF regulated to unity ● 1.0 output PF (kW=kVA) ● Dual AC inputs ● Extended life batteries (5 – 8 yrs) & backup times ● Aesthetically matches data center equipment TM Fig 4.66. Symmetra PX 48 (top) and PX 160 (middle and bottom) ranges. Applications SymmetraTM PX 48 and PX 160 UPSs offer modular protection with hot-scalable power ratings, backup times and distribution for: ● Data centers ● Telecommunications ● Diagnostics and medical imaging ● High-density power zones Colour ● Black Fig. 4.67. Symmetra APC by Schneider Electric TM PX 48 and PX 160 applications 05/2009 edition ch. 4 - p.60 SymmetraTM PX 48 and PX160 UPSs (cont.) Main features True modular design The SymmetraTM is a true modular system. Made up of dedicated and redundant modules - power, intelligence, battery and bypass - all engineered into a design that is easily and efficiently serviceable, this architecture can scale power and runtime as demand grows or as higher levels of availability are required. ● SymmetraTM PX 48 features integrated all-in-one scalable design, with up to three 16 kW power modules (for 48 kW with N+0 or 32 kW with N+1 redundancy), four high-performance battery modules (1 module = 1 row of 4 batteries), main and backup intelligence modules, power distribution modules and a hot-swappable builtin static bypass switch, all in a single cabinet (figure 4.68). Redundant Intelligence Module Hot-Scalable Modular Power Distribution Back-up for the Main Intelligence Module provides increased availability Safely expand and service without forced shutdowns 16kW Power Module Provides the flexibility to scale power capacity in an N+0 or N+1 configuration with fully rated inverters to deliver more real power Wrap Around System Bypass Isolates UPS from critical load while maintaining power to your loads Hot Swappable Built-in Static Bypass Switch High Performance Batteries More powerful batteries help reduce overall system footprint while extended battery life (5 – 8 years) reduces total cost of ownership Fig. 4.68. Symmetra TM Enables the UPS to transfer the load to utility power, without interruption, in case of heavy overload or faulty conditions No Rear Access Space saving & more flexibility on where you place the UPS PX 48 true modular design. ● For scalable ratings up to 160 kW, the SymmetraTM PX 160 offers the same modular design with a power cabinet housing up to ten 16 kW power modules (for 160 kW with N+0 or 144 kW with N+1 redundancy), main and backup intelligence modules and a hot-swappable built-in static bypass switch (figure 4.69). Integrated modular power distribution and batteries can be included in a PDU-XR cabinet (figures 4.69 and 4.70). Integrated Power Distribution & Battery Cabinet (Distribution front / Battery rear) Redundant Intelligence Module Back-up for the Main Intelligence Module provides increased availability Leaves more white space for your IT racks & helps to minimise the total size necessary for your data center 16kW Power Module Hot-Scalable Modular Power Distribution Provides the flexibility to scale power capacity in an N+0 or N+1 configuration with fully rated inverters to deliver more real power Safely expand and service without forced shutdowns Wrap Around System Bypass Isolates UPS from critical load while maintaining power to your loads Hot Swappable Built-in Static Bypass Switch Subfeed breakers Two 160A subfeeds allow additional distribution elements to be integrated into your data center Enables the UPS to transfer the load to utility power, without interruption, in case of heavy overload or faulty conditions TM Fig. 4.69. Front view: Symmetra PX 160 power cabinet (left) and PDU-XR integrated power distribution and battery cabinet (right). APC by Schneider Electric 05/2009 edition ch. 4 - p.61 SymmetraTM PX 48 and PX160 UPSs (cont.) Battery modules are located either in an integrated PDU-XR power distribution and battery cabinet and/or in adjacent XR battery cabinets, both designed for up to 9 high-performance battery modules (1 module = 1 row of 4 batteries) (figures 4.70 and 4.71). REAR VIEW Premium Line-Up and Match Enclosures Matches the look of other IT equipment in your data center High Performance Batteries More powerful batteries help reduce overall system footprint while extended battery life (5 – 8 years) reduces total cost of ownership Battery Module Connected in parallel for increased availability and hot swappable for easy replacement by a trained user TM Fig. 4.70. Rear view: Symmetra PDU-XR integrated power Fig. 4.71. XR battery distribution and battery cabinet (left) beside PX 160 power cabinet cabinet. (right). Availability ● ● Modular design enables fast recovery time. The use of hot-swappable modules boosts availability while reducing operating, maintenance and repair costs. ● Redundant design eliminates single points of failure. ● Standardised, self-diagnosing modules prevent human errors. ● Dual AC inputs increases availability by allowing the UPS to be connected to two separate power sources. ● The possibility of N+1 redundant configurations offers higher availability by providing one more power module than is necessary to support the connected load. Agility ● ● ● Rack-based modular form promotes quick installation and portability. Multiple cable entry points enable flexible installation methods. Scalable power capacity reduces UPS over-sizing costs today by allowing quick upgrades later. ● Scalable batteries allows additional runtime to be quickly added as needed. ● Front-access servicing simplifies installation and maintenance while minimising space requirements (PX 48 only). ● SmartSlot makes it possible to customise UPS communication capabilities with management cards. ● Battery replacement without tools allows quick, easy battery replacement. Total Cost of Ownership ● ● ● ● ● APC by Schneider Electric Scalable power capacity allows right-sizing of UPS to reduce capital outlay. Fully rated inverter (kVA = kW) provides more real power. Self-test and battery management decrease lifetime maintenance costs. Manageable Extended Run Enclosures reduce the need for battery maintenance. Power factor corrected input reduces upstream equipment costs. 05/2009 edition ch. 4 - p.62 SymmetraTM PX 48 and PX160 UPSs (cont.) Unrivalled power density ● ● ● 48 kW of power protection, distribution & backup time in 0.64 m2. 96 kW of power protection, distribution & backup time in 1.28 m2. 160 kW of power protection, distribution & backup time in 1.92 m2. Manageability ● Multi-function status and control console (PowerView) with built-in LCD text or graphic display (fig. 4.72). ● Audible alarms (and visible alarms on display). ● Battery runtime indicated on display. ● Web-enabled remote monitoring (option). Full System Level Display Easy recognition of functions Offers a clear overview of alarms, status data, instructional help and configuration items on UPS and external batteries through a single display The design is harmonized across product lines and the layout resembles that of a computer keyboard Help Key Fault LED Launches context-sensitive help that provides short descriptions of functions When indicator is red a faulty condition exists Status Indicators When green UPS is providing power to the load, the two yellow indicators tell that UPS is on battery or that power is being supplied through the static switch (bypass) Fig. 4.72. Symmetra APC by Schneider Electric TM Navigation Keys Up and Down for easy navigation through menus, Enter key that opens menu items and input changes to system parameters and Escape for returning to previous screen PX 160 PowerView console. 05/2009 edition ch. 4 - p.63 SymmetraTM PX 48 and PX160 UPSs (cont.) Diagram and functions SymmetraTM PX 48 and PX 160 UPSs offer the following equipment and functions: Standard ● Hot-scalable power modules ● Hot-scalable battery modules ● Hot-scalable modular power distribution (for PX 48 and PX 160 with PDU-XR) ● Main and backup intelligence modules ● Hot-swappable built-in static bypass switch ● Multi-function status and control console (PowerView) with built-in LCD text or graphic display ● Wrap-around system bypass Optional ● Additional modular distribution units ● External battery cabinets with slots for 9 battery modules (1 module = 1 row of 4 batteries) Fig. 4.73. Symmetra APC by Schneider Electric TM PX modular diagram 05/2009 edition ch. 4 - p.64 SymmetraTM PX 48 and PX160 UPSs (cont.) Electrical characteristics and communication Power rating (kVA at PF = -0.5 to +0.5) 48 (PX 48) 160 (PX 160) (maximum rated apparent output power) Active power (kW) Up to 48 (hot scalable with 16 kW modules) Up to 160 (hot scalable with 16 kW modules) Input (rated values and tolerances where applicable) Number of phases 3+N (1) Voltage Normal AC input 380 / 400 / 415 V 3-phase Tolerances for 400V: 304 to 477 V at full load, 200 to 477 V at half load Bypass AC input 380 / 400 / 415 V Tolerances: ± 10% Frequency Normal AC input 40-70Hz with 10Hz/sec slewrate Bypass AC input 50 or 60 Hz ± 0.1 Hz, ± 3 Hz, ± 10 Hz (user selectable) Power factor >0.99 at >50% load, >0.95 at > 15% load, >0.90 at > 10% load (2) THDI <5% at full load Currents See the "input and output currents" table below Output (rated values and tolerances where applicable) Number of phases 3+N Voltage 380 / 400 / 415 V ± 1% (100% linear load) or ± 3% (100% non-linear load) Frequency AC power sync 50 or 60 Hz ± 3% (user adjustable to ± 1%) free running 50 or 60 Hz ± 0.1% Power factor 0.5 leading to 0.5 lagging without any derating (3) THDU linear load < 2% for 100% linear load, non-linear load < 6% for 100% non-linear load according to IEC/EN62040-3 Currents See the "input and output currents" table below Short-circuit capacity (without bypass) 35kAIC Bypass short-circuit capacity 35kAIC Overload capacity Normal operation 150% for 60 s, 125% for 10 min. 150% for 60 s, 125% for 10 min. Battery operation 150% for 60 s 150% for 60 s Crest factor Unlimited Voltage transients during ± 5% for 100% load step load step changes Maximum frequency variation 40Hz-60Hz or 50Hz to 70Hz depending on output frequency selected. Selectable slew rate from 0.25 Hz/sec to 6 Hz/sec Efficiency At 35-100% load Normal operation ≥95% Battery operation ≥94% Conditions for transfer to AC bypass Acceptable difference in voltage Selected voltage (380V, 400V, 415V) +/-10 % Synchronisation frequency range +/- 10 Hz, i.e. 40Hz to 60Hz or 50Hz to 70Hz depending on output frequency selected Battery Type Sealed lead-acid Service life 5-8 years (4) Backup time Built-in Depends on load and number of battery modules Depends on load and number of battery modules (4 modules max.) (9 modules max.) XR battery cabinet Depends on load and number of battery modules Depends on load and number of battery modules (9 modules max.) (9 modules max.) Communication Standard Multi-function status and control console (PowerView) with built-in LCD text or graphic display Audible alarms (and visible alarms on display) Emergency power off (EPO) Battery runtime indicated on display Web-enabled remote monitoring (monitoring service required) Options Network Management Card Dry Contact Management Environmental Monitor Card Building Management System Card (MODBUS/JBUS) (1) other voltages on request 208, 220, 480 V, 660 V… (2) THDI (Total Harmonic Distortion - I for current) (3) THDU (Total Harmonic Distortion - U for voltage) (4) For runtimes for various loads and configurations, see http://www.apc.com/products/runtime_for_extendedruntime.cfm . APC by Schneider Electric 05/2009 edition ch. 4 - p.65 SymmetraTM PX 48 and PX160 UPSs (cont.) Physical characteristics, environment and standards Power rating (kVA at PF = -0.5 to +0.5) 48 (PX 48) 160 (PX 160) (maximum rated apparent output power) Active power (kW) Up to 48 (hot scalable with 16 kW modules) Up to 160 (hot scalable with 16 kW modules) Dimensions and weight of power frame Height (mm) 2000 2000 Width (mm) 600 600 Depth (mm) 1070 1070 Weight (kg) 537 (16 kW) 666 (32 kW) 796 (48 kW) 578 Dimensions and weight of distribution/battery cabinet (PDU-XR) for PX 160 Height (mm) n/a 2000 Width (mm) n/a 600 Depth (mm) n/a 1070 Weight fully loaded (kg) n/a 1273 Dimensions and weight of additional battery cabinets (XR) (fully equipped with 9 battery modules) Height (mm) 2000 2000 Width (mm) 600 600 Depth (mm) 1070 1070 Weight fully loaded (kg) 1270 1270 Environment Noise level (dBA) <61 < 63 Degree of protection (as per IEC 60529) IP 20 IP 20 Maximum altitude without derating 1000 m 1000 m Temperature range Without battery -30°C to 70°C for storage With battery -15°C to 40°C Temperature range Inverter -30°C to 70°C for storage Battery possible: 0 to 40°C (40°C for 8 hours, 35°C for 24 hours) optimum: + 15°C to + 25°C (service life is reduced by half for every 10° above 25°C) Standards Construction and safety IEC 62040-1 / IEC 60950 / EN 62040-1 Performance and topology IEC 62040-3 / EN 62040-3 EMC IEC 62040-2 / EN 62040-2 level B / EN 55011 and EN 55022 level B / FCC part 15 Harmonics IEC 61003-2 / IEC 61003-4 Design and manufacture ISO14001 / ISO 9001 Certification and marking TÜV / CE APC by Schneider Electric 05/2009 edition ch. 4 - p.66 SymmetraTM PX 48 and PX160 UPSs (cont.) Currents values for choice of protection characteristics Power rating (kVA at PF = -0.5 to +0.5) (maximum rated apparent output power) Active power (kW) Input and output currents 48 (PX 48) 160 (PX 160) Up to 48 (hot scalable with 16 kW modules) Up to 160 (hot scalable with 16 kW modules) Currents and measurement conditions ● I1 : input current on Normal AC input N.B. These currents are measured for: - full rated load for PF = 0.8; - a rated Normal AC input voltage of 400 V; - battery float charging. For rated Normal AC input voltages of 380 V and 415 V, multiply the indicated I1 and Iu values by 1.05 and 0.96 respectively. ● Iu : load current ● Ibmax. maximum battery current Fig. 4.74. Input and output currents. Max. input current I1 (A) for 10 min. backup time - batteries charging (Given the high level of scalability of these products, please consult us for current values corresponding to your installation) Load current Iu (A) Max. battery output current Ibmax (A) APC by Schneider Electric 05/2009 edition ch. 4 - p.67 SymmetraTM PX 250/500 UPSs Presentation Up to 2000 kW of high-efficiency power protection with breakthrough scalability and advanced modularity. SymmetraTM PX 250/500 ● Hot-scalable in 25 kW increments up to 250 kW (1 power frame) or 500 kW (2 power frames) ● 250 kW configuration expandable to 500 kW ● 2000 kW configurations by parallel connection of up to 4 units ● Three-phase input and output ● Fully modular design (power, 250 kW configuration batteries, intelligence and communication) ● Hot scalable power & backup time ● Hot swappable internal bypass static switch ● Side-mounted maintenance bypass with distribution (option) ● High power density ● 96% efficiency down to 50% load ● Large touch-screen graphical user interface 500 kW configuration ● On-line double conversion ● Input PF regulated to unity ● 1.0 output PF (kW=kVA) ● Dual mains ● Extended life batteries (5 – 8 yrs) & backup times ● Aesthetically matches data center equipment TM Fig 4.75. Symmetra ● No rear access required PX 250/500 configurations Applications SymmetraTM PX 250/500 UPSs offer high-efficiency modular protection with hotscalable power ratings and backup times for: ● Medium to large data centers ● High-density power zones TM Fig 4.76. Symmetra PX 250/500 applications Colour ● APC by Schneider Electric Black Edition - 05/2009 ch. 4 - p.68 SymmetraTM PX 250/500 UPSs (cont.) Main features True modular design The SymmetraTM is a true modular system (fig. 4.77). Made up of dedicated and redundant modules--power, intelligence, battery and communications, all engineered into a design that is easily and efficiently serviceable, this architecture can scale power and runtime as demand grows or as higher levels of availability are required. ● For scalable ratings up to 500 kW, the SymmetraTM PX 250/500 includes one or two power cabinets each housing up to ten 25 kW power modules (for up to 250 or 500 kW) and an input/output cabinet housing a built-in bypass static switch and redundant intelligence modules. The battery modules are located in separate battery cabinets. ● The use of hot-swappable modules boosts availability while reducing operating, maintenance and repair costs. Ultra-High Efficiency Power Module Dual Mains Input/Output Maintenance Bypass with Distribution (MBwD) Provides the flexibility to scale power capacity in 25kW Increments and adds N+1 capability as well as a fully rated inverter for providing more real power Allows for connection to 2 separate power inputs for increased availability – top or bottom Space saving design that provides power distribution to your load and if required isolation from the UPS while maintaining power to your critical loads Long Life Battery Module Built-in Static Bypass Switch Connected in parallel for increased availability the 5-8yr expected life reduces systems lifetime costs (TCO) Hot swappable, the SSW enables the UPS to transfer the load to utility power, without interruption, in case of heavy overload or faulty conditions Premium Line-Up/Remote External Battery Enclosure Redundant Intelligence Module A total of eight (8) enclosures can be connected to the UPS for extended runtimes and availability Back-up for the Main Intelligence Module provides increased availability TM Fig 4.77. Symmetra No Rear Access Space saving & More flexibility on where you place the UPS PX 250/500 true modular design. Availability ● ● ● ● Modular design enables fast recovery time Redundant design eliminates single points of failure Standardised, self-diagnosing modules prevent human errors Dual mains input increases availability by allowing the UPS to be connected to two separate power sources ● The possibility of N+1 redundant configurations offers higher availability by providing one more power module than is necessary to support the connected load ● Maximum battery life and reliability through intelligent, precision charging ● Redundant intelligence modules provide higher availability to the UPS connected loads by giving redundant communication paths to critical UPS functions Agility ● ● ● Rack-based modular form promotes quick installation and portability Multiple cable entry points enable flexible installation methods Scalable power capacity reduces UPS over-sizing costs today by allowing quick upgrades later. ● Scalable batteries allows additional runtime to be quickly added as needed. ● Front-access servicing simplifies installation and maintenance while minimising space requirements. ● SmartSlots make it possible to customise UPS capabilities with management cards. ● Battery replacement without tools allows quick, easy replacement. APC by Schneider Electric Edition - 05/2009 ch. 4 - p.69 SymmetraTM PX 250/500 UPSs (cont.) Total Cost of Ownership ● ● ● ● Scalable power capacity allows right-sizing of UPS to reduce capital outlay Fully rated inverter (kVA = kW) provides more real power Self-test and battery management decrease lifetime maintenance costs Manageable external batteries reduces preventative maintenance service needs by monitoring the health and status of the external batteries and their expected runtime ● Power factor corrected input reduces upstream equipment costs Unrivalled power density ● ● 250 kW of power protection in 3.3 m2 (including battery footprint) 500 kW of power protection in 5.7 m2 (including battery footprint) Manageability ● Microprocessor-controlled user interface with 10.4" multicolour graphical display and touch screen control (fig. 4.78) ● Audible alarms (and visible alarms on display) ● Emergency power off (EPO) ● Web-enabled remote monitoring (option) Full Screen Menus Easy to follow menus provide step-by-step start up, shut down and system configuration mitigating the risk of error. 10” LCD Touch Screen Display Offers a clear graphical / text based overview of alarms, status data, instructional help that minimize the risk of operator errors Summary Screens Graphical Summary screens provide clear status information for easier system management System Wide Firmware Updates Diagnostic Screens Quickly and Easily identify component problems & errors, reducing mean time to repair On-the-fly upgrades via USB port on back of display. Makes firmware updates easy and increases system availability TM Fig 4.78. Symmetra APC by Schneider Electric PX 250/500 user interface. Edition - 05/2009 ch. 4 - p.70 SymmetraTM PX 250/500 UPSs (cont.) Diagram and functions SymmetraTM PX 250/500 UPSs offer the following equipment and functions: Standard ● Hot-scalable power modules ● Hot-scalable battery modules ● Hot-swappable built-in static bypass switch ● Main and backup intelligence modules ● Microprocessor-controlled user interface with 10.4" multicolour graphical display and touch screen control Optional ● Maintenance bypass cabinet with distribution (MBwD) ● External battery cabinets ● Web-enabled remote monitoring TM Fig 4.79. Symmetra APC by Schneider Electric PX modular diagram. Edition - 05/2009 ch. 4 - p.71 SymmetraTM PX 250/500 UPSs (cont.) Electrical characteristics and communication Power rating (kVA at PF = -0.5 to +0.5) 250/500 (maximum rated apparent output power) Active power (kW) 1 power frame Up to 250 (hot scalable with 25 kW modules in 1 power frame) or 225 with N+1 redundancy 2 power frames Up to 500 (hot scalable with 25 kW modules in 2 power frames) or 475 witt N+1 redundancy Parallel connection Up to 2000 with parallel connection of four 500 kW units Input (rated values and tolerances where applicable) Number of phases 3+N (1) Voltage Normal AC input 380 / 400 / 415 V 3-phase Tolerances: ± 15% for full performance Bypass AC input 380 / 400 / 415 V Tolerances: ± 10% (adjustable to ± 4 / 6 / 8 / 10%) Frequency Normal AC input 40-70Hz with 10Hz/sec slewrate Bypass AC input 50 or 60 Hz ± 3 Hz Tolerances (user selectable from ± 0.5% to ± 8% on front panel) Power factor >0.995 at 100% load (2) THDI <5% at full load Currents See the "input and output currents" table below Output (rated values and tolerances where applicable) Number of phases 3+N Voltage 380 / 400 / 415 V ± 1% for 100% linear or non-linear load Frequency AC power sync 50 or 60 Hz ± 3% (user adjustable to ± 1%) free running 50 or 60 Hz ± 0.1% Power factor 0.5 leading to 0.5 lagging without any derating (3) THDU linear load < 2% for 100% linear load, non-linear load < 6% for 100% non-linear load according to IEC/EN62040-3 Currents See the "input and output currents" table below Overload capacity Normal operation 150% for 30 s, 125% for 10 min Battery operation 125% for 30 s Crest factor Unlimited Voltage transients during ± 5% for 0-100% or 100-0% load step load step changes Efficiency At 50-100% load Normal operation ≥96% Battery operation ≥95% Battery Type Sealed lead-acid Service life 5-8 years (5) Backup time Depends on load and number of battery modules installed (8 rows of 6 batteries per cabinet) Communication Standard Microprocessor-controlled user interface with 10.4" multicolour graphical display and touch screen control Audible alarms (and visible alarms on display) Emergency power off (EPO) Battery runtime indicated on display Options Web-enabled remote monitoring Relay interface board for dry contacts (1) other voltages on request 208, 220, 480 V, 660 V… (2) THDI (Total Harmonic Distortion - I for current) (3) THDU (Total Harmonic Distortion - U for voltage) (4) For runtimes for various loads and configurations, see http://www.apc.com/products/runtime_for_extendedruntime.cfm . APC by Schneider Electric Edition - 05/2009 ch. 4 - p.72 SymmetraTM PX 250/500 UPSs (cont.) Physical characteristics, environment and standards Power rating (kVA at PF = -0.5 to +0.5) 250/500 (maximum rated apparent output power) Active power (kW) 1 power frame Up to 250 (hot scalable with 25 kW modules in 1 power frame) or 225 with N+1 redundancy 2 power frames Up to 500 (hot scalable with 25 kW modules in 2 power frames) or 475 witt N+1 redundancy Parallel connection Up to 2000 with parallel connection of four 500 kW units Dimensions and weight of power frame Height (mm) 2000 Width (mm) 600 Depth (mm) 1070 Dimensions and weight of battery cabinet (XR) Height (mm) 2000 Width (mm) 600 Depth (mm) 1070 Weight fully loaded (kg) 1475 Dimensions of input/output cabinet Height (mm) 2000 Depth (mm) 1070 Dimensions of MBwD cabinet Height (mm) 2000 Depth (mm) 1070 Environment Noise level (dBA) 54 dBA at 100% load, 45 dBA at 70% load Maximum altitude without derating 1000 m Temperature range Without battery -30°C to 70°C for storage With battery -15°C to 40°C Temperature range Inverter 0°C to 40°C for operation Battery possible: 0 to 40°C (40°C for 8 hours, 35°C for 24 hours) optimum: + 15°C to + 25°C (service life is reduced by half for every 10° above 25°C) Standards Construction and safety IEC 62040-1 / IEC 60950 / EN 62040-1 Performance and topology IEC 62040-3 / EN 62040-3 EMC IEC 62040-2 / EN 62040-2 level B / EN 55011 and EN 55022 level B / FCC part 15 Harmonics IEC 61003-2 / IEC 61003-4 Design and manufacture ISO14001 / ISO 9001 Certification and marking TÜV / CE APC by Schneider Electric Edition - 05/2009 ch. 4 - p.73 SymmetraTM PX 250/500 UPSs (cont.) Currents and protection characteristics Power rating (kVA at PF = -0.5 to +0.5) 250/500 (maximum rated apparent output power) Active power (kW) 1 power frame Up to 250 (hot scalable with 25 kW modules in 1 power frame) or 225 with N+1 redundancy 2 power frames Up to 500 (hot scalable with 25 kW modules in 2 power frames) or 475 witt N+1 redundancy Parallel connection Up to 2000 with parallel connection of four 500 kW units Input and output currents Currents and measurement conditions ● N.B. These currents are measured for: ● full rated load for PF = 0.8; ● a rated Normal AC input voltage of 400 V; ● battery float charging. For rated Normal AC input voltages of 380 V and 415 V, multiply the indicated I1 and Iu values by 1.05 and 0.96 respectively. I1 : input current on Normal AC input ● Iu : load current ● Ibmax. maximum battery current Fig 4.80. Input and output currents. Max. input current I1 (A) for 10 min. backup time - batteries charging (Given the high level of scalability of these products, please consult us for current values corresponding to your installation) Load current Iu (A) Max. battery output current Ibmax (A) APC by Schneider Electric Edition - 05/2009 ch. 4 - p.74 SymmetraTM MW UPSs Presentation Ultra-high efficiency power protection for medium to large data centers, buildings and facilities. SymmetraTM MW ● 400 kW to 4000 kW ● Ultra-high efficiency for low TCO ● Modular design ● Fault tolerant ● Scalable power ● Parallel capable for capacity or redundancy ● Robust platform design ● Universal battery support ● Network manageable TM Fig 4.81. Symmetra MW Applications SymmetraTM MW offers 3-phase modular, scalable power protection with industry leading efficiency, capacity and performance for: ● Medium to large data centers ● Buildings ● Facilities Colour ● Light grey TM Fig 4.82. Symmetra APC by Schneider Electric MW applications 05/2009 edition ch. 4 - p.75 SymmetraTM MW UPSs Main features Modular design ● Three sections: inverter section with 66.7 kW power modules in 200 kW frames, control section and input.output section. Control Section: LCD Touch-screen Configurable touch-screen with network interface offers easy access to all critical UPS and ancillary equipment data. High Efficiency Input/Output Section Spacious cable section for ease of installation. Top or bottom, left or right side cable entry. Up to 97% efficiency at full load provides reduced heat dissipation and energy costs Inverter Section Control Section: Static Bypass Switch Load-sharing 200 kW power modules provide the flexibility to scale power capacity and adds N+1 capability The built-in static bypass switch (400 and 600kW models) provides for safe transfer to an alternate source without interrupting the supply to the load TM Fig 4.83. Symmetra MW modular design. Ultra-high efficiency High efficiency means lower power cost per watt delivered to critical equipment. It also means less heat rejection and lower cooling costs. ● > 97% efficiency at > 85% load ● > 96% efficiency at > 45% load ● > 94% efficiency at > 24% load Line Voltage -15% Line Voltage Nominal -- Line Voltage +15% TM Fig 4.84. Symmetra MW efficiency. Scalable power capacity ● Available power can be scaled to optimize loading or to allow expansion as needed. ● Ratings can be scaled for redundancy or capacity ● Buy for the future, populate for current load ● Easy parallel connection of multiple units of mixed sizes APC by Schneider Electric 05/2009 edition ch. 4 - p.76 SymmetraTM MW UPSs Fault tolerance and simplified maintenance Modular inverters insure robust performance, easy maintenance, and rapid repairs without jeopardizing the critical load. ● Power modules can be added or changed by one person ● Individual containment assures isolation of components. ● Standardized modular components simplify stocking spares. Manageability ● Advanced 10" touch screen LCD displays system status, power flow and metering information ● Web/Network interface (Ethernet, SNMP) ● Audible and visual alarms prioritised by severity ● Self-diagnosing with surveillance of critical components ● Emergency power off (EPO) ● Connectivity with InfraStruXureTM Central monitoring system InfraStruXureTM Central provides an efficient way for organizations to monitor their companywide multi-vendor physical infrastructure: power, cooling, security, and environment. Real-time monitoring, user-defined reports and graphs, and instant fault notification and escalation enable quick assessment and resolution of critical infrastucture events that can adversely affect IT system availability. This centralized respository of critical information can be accessed by multiple users from anywhere on the network, creating a consolidated view of the physical infrastructure. Fig 4.85. InfraStruXure APC by Schneider Electric TM Central monitoring system from APC by Schneider Electric 05/2009 edition ch. 4 - p.77 SymmetraTM MW UPSs Diagram and functions SymmetraTM MW UPSs offer the following equipment and functions: Standard ● Inverter section with 66.7 kW power modules in 200 kW frames ● Control section including static bypass switch ● Input/output section ● Advanced 10" touch screen LCD displays system status, power flow and metering information Web/Network interface (Ethernet, SNMP) ● Audible and visual alarms prioritised by severity ● Self-diagnosing with surveillance of critical components ● Emergency power off (EPO) Matched to customer needs ● External battery cabinets ● Battery disconnect circuit-breaker cabinet ● Maintenance bypass cabinet TM Fig 4.86. Symmetra APC by Schneider Electric MW diagram. 05/2009 edition ch. 4 - p.78 SymmetraTM MW UPSs (cont.) Electrical characteristics and communication Power rating (kVA at PF = -0.8 to +0.9) 400 600 800 1000 1200 1400 1600 (maximum rated apparent output power) Active power (kW) 1 power frame Scalable from 400 to 1600 kW in 200 kW increments Parallel connection Up to 4000 kW with parallel connection of multiple units Input (rated values and tolerances where applicable) Number of phases 4-wire 3-phase + PE 4-wire 3-phase + PEN 5-wire 3-phase + N + PE (1) Voltage Normal AC input 380 / 400 / 415 / 3-phase Tolerances: ± 15% Bypass AC input 380 / 400 / 415 V Tolerances: ± 10% (adjustable to ± 4 / 6 / 8 / 10%) Frequency Normal AC input 50 or 60 Hz (programmable ± 0.5 / 1/ 2 / 4 / 6 / 8%) Bypass AC input 50 or 60 Hz Power factor ~1 (2) THDI <5% at full load Currents See the "input and output currents" table below Output (rated values and tolerances where applicable) Number of phases 4-wire 3-phase + PEN 5-wire 3-phase + N + PE Voltage 380 / 400 / 415 V ± 1% for 100% balance linear load (± 3% for unbalanced linear load) Frequency AC power sync 50 or 60 Hz (programmable ± 0.5 / 1/ 2 / 4 / 6 / 8%) free running 50 or 60 Hz ± 0.1% Power factor 0.9 leading to 0.8 lagging without any derating (3) THDU linear load < 3% for 100% linear load, non-linear load < 5% for 100% non-linear load Currents See the "input and output currents" table below Short-circuit capacity (without bypass) 100 kA (symmetrical amps) Bypass short-circuit capacity 100 kA (symmetrical amps) Overload capacity 200% for 60s, 125% for 10 min. Crest factor Unlimited Voltage transients during ± 5% for 100% load step ± 3% for 50% load step load step changes Voltage and phase imbalance ± 1% for 100% balanced linear load, ± 1° for 50% current unbalance ± 3% for 100% unbalanced linear load, ± 3° for 100% current unbalance Maximum frequency variation ± 0.5 to 8% (adjustable via display) Efficiency At 85 to100% load Normal operation ≥97% Battery operation ≥95% Conditions for transfer to AC bypass Acceptable difference in voltage ± 5% for operator requested transfers Synchronisation frequency range ±0.1% Battery Type No internal battery - uses external battery system Service life n/a (4) Backup time Depends on load and type of external battery system used . Communication Standard Advanced 10" touch screen LCD displays system status, power flow and metering information, TM supports InfraStruXure Central connectivity. Web/Network interface (Ethernet, SNMP) Audible and visual alarms prioritised by severity Self-diagnosing with surveillance of critical components Battery runtime indication on display Emergency power off (EPO) Options (1) other voltages on request: (2) THDI (Total Harmonic Distortion - I for current) (3) THDU (Total Harmonic Distortion - U for voltage) (4) For runtimes for various loads and configurations, contact your APC by Schneider Electric representative. APC by Schneider Electric 05/2009 edition ch. 4 - p.79 SymmetraTM MW UPSs (cont.) Physical characteristics, environment and standards Power rating (kVA at PF = -0.8 to +0.9) 400 600 800 1000 1200 1400 (maximum rated apparent output power) Active power (kW) 1 power frame Scalable from 400 to 1600 kW in 200 kW increments Parallel connection Up to 4000 kW with parallel connection of multiple units Dimensions and weight of inverter section Height (mm) 2032 2032 2032 2032 2032 2032 Width (mm) 2111 1268 1690 2112 2x1268 1268+1690 Depth (mm) 1067 1067 1067 1067 1067 1067 Weight (kg) 2463 2430 3136 3990 4860 5566 Dimensions and weight of control section Height (mm) Combined 2032 2032 2032 2032 2032 Width (mm) Combined 1268 1013 1013 2110 2110 Depth (mm) Combined 1067 1067 1067 1067 1067 Weight (kg) Combined 938 610 610 1372 1372 Dimensions and weight of input/output section Height (mm) Combined Combined 2032 2032 Combined Combined Width (mm) Combined Combined 1013 1013 Combined Combined Depth (mm) Combined Combined 1067 1067 Combined Combined Weight (kg) Combined Combined 480 480 Combined Combined Environment Noise level (dBA) <75 dBA Degree of protection (as per IEC 60529) IP 20 Maximum altitude without derating 1000 m Overload capacity Normal operation 200% for 60 s, 125% for 10 min Battery operation 150% for 30 s Temperature range Without battery -15 to 40°C for extended storage; -50 to 55°C for short-time storage or transportation for storage With battery -15°C to 40°C Temperature range Inverter 0 to 40°C (operating) for operation Battery possible: 0 to 40°C (40°C for 8 hours, 35°C for 24 hours) optimum: + 15°C to + 25°C (service life is reduced by half for every 10° above 25°C) Standards Construction and safety IEC 60950 3rd. edition, EN50091-1-1, UL 1778 (CSA for Canada) Performance and topology IEC 62040-3 / EN 62040-3 EMC/EMI/RFI IEC 62040-2 / EN 62040-2 level B / EN 55011 and EN 55022 level B / FCC part 15 Harmonics IEC 61003-2 / IEC 61003-4 Design and manufacture ISO14001 / ISO 9001 Certification and marking TÜV / CE, UL and Canadian UL APC by Schneider Electric 05/2009 edition 1600 2032 2x1690 1067 6272 2032 2110 1067 1372 Combined Combined Combined Combined ch. 4 - p.80 SymmetraTM MW UPSs (cont.) Currents and protection characteristics Power rating (kVA at PF = -0.8 to +0.9) 400 600 800 1000 (maximum rated apparent output power) Active power (kW) 1 power frame Scalable from 400 to 1600 kW in 200 kW increments Parallel connection Up to 4000 kW with parallel connection of multiple units Input and output currents 1200 1400 1600 ● I1 : input current on Normal AC input ● Iu : load current ● Ibmax. maximum battery current Max. input current I1 (A) for 10 min. backup time - batteries charging, 10% of UPS rating (optional 20% with UPS derated 10%. i.e 1000kW ~ 900kW ) Load current Iu (A) Max. battery output current Ibmax (A) APC by Schneider Electric Fig 4.87. Input and output currents. 679 1019 1358 738 577 638 1108 866 957 1477 1155 1277 05/2009 edition 1696 2108 2458 2809 1845 1443 1596 2293 1793 1917 2674 2091 1337 3055 2390 2556 ch. 4 - p.81 MGETM SineWaveTM active harmonic conditioner Presentation The solution for harmonic disturbances of medium-power infrastructure, commercial and industrial applications. MGETM SineWaveTM ● 6 power ratings: 20 - 30 - 45 - 60 - 90 - 120 A ● Parallel connection of up to four units, i.e. up to 480 A ● Real-time IGBT and DSP-based harmonic compensation ● Three-phase for harmonic currents on all three phases and the neutral ● Independent of the source Fig. 4.88. MGE TM TM SineWave . Applications MGETM SineWaveTM active harmonic conditioners eliminate upstream of their point of installation the current harmonics caused by the downstream non-linear loads. Digital design means the type of elimination may be selected: Overall elimination of all harmonic orders from H2 to H25. Selective elimination for specific orders. They are also the means to limit the upstream voltage total harmonic distortion THDU to a selected value (generally 5 to 8%), depending on what is acceptable for sensitive equipment or for the public distribution systems. MGETM SineWaveTM can be used in all types of distribution systems confronted with harmonics, in view of: Solving problems in existing installations. Preventing problems in new installations. MGETM SineWaveTM is compatible with all types of loads (e.g. single-phase computer loads, three-phase variable speed drives or rectifiers, or a mix of single-phase and three-phase loads). It is independent of the power source and effectively conditions harmonics, even if the installation is subsequently modified. A number of conditioners can be used at different points in the installation or parallel connected. Colour Light grey RAL 9002. For other colours, please consult us. source sinusoidal source current I + IH required harmonic currents SineWave SineWave harmonic currents I + IH measurement of harmonic currents = current drawn by loads loads The load current includes harmonics that deform the sinusoidal waveform of the TM source current. MGE TM SineWave , in real time: ● measures the various harmonics using toroid sensors, ● injects upstream of the load the currents corresponding to the harmonics (1). These IH currents are added to the source current to supply the loads with the necessary waveform. The harmonics are supplied by TM TM MGE SineWave and the source current remains sinusoidal. (1) For each harmonic with an order k, for which the rms current and phase, as measured by the toroids, are Ik and φk, SineWave injects a current waveform: I = Ik 2 sin (2πkf t + φk) Fig. 4.89. MGE APC by Schneider Electric TM SineWave TM 05/2009 edition operating principle. ch. 4 - p.82 MGETM SineWaveTM active harmonic conditioner (cont.) Main features Overall or selective elimination of harmonic currents MGETM SineWaveTM effectively reduces current harmonics (by a factor of 10 or 20) over the entire harmonic spectrum from H2 to H25 or selected harmonic orders (user set). Improved cos MGETM SineWaveTM also improves: The displacement factor (cos ), The power factor (). Easy integration throughout the installation MGETM SineWaveTM can be set up very easily in all types of existing and new installations due to a number of features. Compatibility with all types of loads. MGETM SineWaveTM automatically adapts to different loads, whatever their harmonic spectrum. Independent from the power source. Operation does not depend on the source and is therefore highly effective with different sources, including engine generator sets. Easy to install. The system simply requires three-phase power (with or without a neutral) and installation of the measurement sensor (split toroid) on the circuit supplying the concerned load. Set-up with two current transformers, one on the TM TM switchboard incomer and the other on the MGE SineWave incomer, facilitates installation in switchboards with outgoers that are difficult to access. Small dimensions. Compact design means it can fit anywhere, even on existing sites with little free space. Upgradeable. Parallel connection is possible to increase the conditioning capacity. Exceptional operating dependability MGETM SineWaveTM implements a conditioning technique termed "second generation" that calls on the "in-the-field" experience gained by the first generation of conditioners marketed by APC by Schneider Electric in 1994. The second generation offers: IGBT technology with microprocessor control. A real-time digital micro-controller (DSP) for the harmonic currents. Its design means it is totally protected from overloads. If the requested load current exceeds its capacity, it simply continues to supply the rated amount of current. User friendly The easy human-machine interface (HMI) is seven languages can be used for: Help in system start-up and maintenance, Setting up the conditioning parameters (overall or selective), Easy operation (status conditions, measurements, alarms, orders). TM TM MGE SineWave can also be fitted out with an optional JBus/RS485 communication interface. Reduction in operating costs MGETM SineWaveTM means substantial savings and a fast return on investment, occasionally in less than two years. This is due to a number of factors. Reduction in energy bills. The elimination of harmonics and the improvement in the cos are the means, respectively, to reduce the kVA drawn and avoid fines from power suppliers. Increase in the service life of the protected equipment. The reduction in the rms current (due to the elimination of harmonics) contributes to extending the service life of equipment by as much as 30%. Improved operating conditions and compliance with standards. By reducing TM TM harmonic distortion on the upstream distribution system, MGE SineWave eliminates the risks of malfunctions in sensitive applications connected to the same source. It is also the means to comply with the contract conditions imposed by the power supplier or by standards concerning harmonic current and voltage distortion levels, thus avoiding fines. APC by Schneider Electric 05/2009 edition ch. 4 - p.83 MGETM SineWaveTM active harmonic conditioner (cont.) MGETM SineWaveTM active harmonic conditioners are small, compact units ready for use. The measurement toroids must simply be placed on the circuit supplying the load. MGETM SineWaveTM units offer the following equipment and functions. Diagram and functions Sinusoidal source current Load current containing harmonics IL IF Source IH Injection of required harmonics Digital measurement for each order Inverter Regulation and monitoring Non-linear Load Measurement of harmonic currents Standard ● Microprocessor-controlled IGBT-based system designed to supply harmonic currents ● Real-time digital micro-controller (DSP) for the harmonic currents ● Toroid sensors (split) ● Diagnostics and maintenance system. ● Parallel connection of up to four units ● Alphanumeric display in seven languages ● Three operating LEDs ● Functions: - overall harmonic conditioning from H2 to H25 - selective harmonic conditioning of one or more harmonic orders - improvement of the displacement factor (cos ) - improvement of the power factor () - access to status conditions, measurements and alarms Optional ● A dry contact for remote indications. ● Remote display. ● RS485 JBus/Modbus communication Active harmonic conditioner interface Fig. 4.90. Simplified diagram. APC by Schneider Electric 05/2009 edition ch. 4 - p.84 MGETM SineWaveTM active harmonic conditioner (cont.) Characteristics Rated current 20 30 45 60 90 120 Conditioning capacity (A) 20 60 30 90 45 135 60 180 90 270 120 360 Voltage (source) 3 phases with or without neutral (can operate with single-phase or unbalanced loads) 400 V -20% + 15% three-phase (208 V, 220 V and 440 V on request) 50 or 60 Hz ± 8% per phase (A) (1) in the neutral (A) Electrical input characteristics Number of phases Frequency Current transformers CT upstream of the load Technical characteristics Conditioned harmonic currents Harmonic attenuation Displacement-factor correction (cos ) Displacement-factor correction () Response time Overload Inrush current Losses (W) Parallel connection Communication Standard Optional Dimensions, weight Height (mm) Width (mm) Depth (mm) Weight (kg) Environment Noise level (dBA) ISO 3746 Losses (W) Degree of protection (as per IEC 529) Storage temperature range Operating temperature range Maximum altitude without derating Standards Performance and topology Safety EMC Emissions conducted, radiated Immunity electrostatic discharges radiated fields low-energy pulses surges Design, manufacturing (1) (2) Ratings of 300/1, 500/1, 600/1, 1000/1, 1500/1, 2000/1, 3000/1, 4000/1 Orders 2 to 25, total or selective conditioning (order by order) (2) THDI load / THDI system > 10 at rated capacity of the conditioner Adjustable up to 0.94 Up to 1 40 ms Limits to rated current, continuous operation while limiting is possible < 2 x the rated peak current 1000 1300 2100 2600 4200 Up to four units 5200 Alphanumeric display in seven languages 3 indication LEDs for operation 3 dry contacts for remote indications Remote display unit RS485 JBus/ModBus card 680 540 280 65 780 590 325 110 < 55 < 55 < 60 1000 1300 2100 IP20 - 25°C to + 70°C dry heat 0 to 40°C daily average (< 25°C recommended) 1000 metres 2 x 720 + 250 220 < 60 2600 < 65 4200 < 65 5200 IEC 62040-3 / EN 50091-3 IEC 60950 / EN 50091-1 IEC 61000-4-2 level 3 / EN 55011 class A IEC 61000-4-2 level 3 IEC 61000-4-3 level 3 IEC 61000-4-4 level 3 IEC 61000-4-5 level 3 ISO14001 / ISO 9001 Maximum values for non-linear computer loads such as PCs. THDI (Total Harmonic Distortion for current). APC by Schneider Electric 05/2009 edition ch. 4 - p.85 MGETM UpsilonTM STS static transfer switch Presentation High-availability redundant power MGETM UpsilonTM STS ● 7 ratings: 30 - 60 - 100 - 160 - 250 400 - 630 A ● Power ratings from 20 to 1100 kVA (at 400 V) ● 3 or 4 poles ● Automatic or manual transfer between sources ● Static transfer technology ● Transfer with no transient crossconduction ● Maintenance bypass on each incomer Fig. 4.91. MGE TM Upsilon TM STS. Applications MGETM UpsilonTM STS static transfer switches are the means to set up, secure and optimise redundant power sources for data centers as well as for industrial and commercial processes. When combined with MGETM GalaxyTM 5000, 7000 or 9000 UPS units and synchronisation modules, they constitute a redundant architecture (see fig. 4.92) offering the exceptional reliability up to the six nines (99.9999%) required by certain installations such as data centres. Fig. 4.92. Example of a multi-source architecture with MGE TM Upsilon TM STS. Colour Light grey RAL 9023. For other colours, please contact us. APC by Schneider Electric 05/2009 edition ch. 4 – p. 86 MGETM UpsilonTM STS static transfer switch (cont.) Main features Seamless static transfer Using IGBT semiconductor technology, MGETM UpsilonTM STS transfers to the second source in 5 milliseconds, i.e. two times faster than the requirements stipulated by computer manufacturers (CBEMA requirements) and well within the requirements of standard IEC 62040. Permissible voltage limits (as a percentage of the rated voltage), depending on the number of cycles (0.5 cycles corresponds to 10 ms) on a log scale. TM Fig. 4.93. CBEMA requirements and MGE Upsilon TM STS operating curve. Control over faults and installation safety Transfer with no transient cross-conduction TM TM MGE Upsilon STS implements transfer with no transient cross-conduction. This "no-overlap" technique ensures that the two sources are never connected in parallel during the transfer, thus avoiding any risk of fault propagation between the sources. Individually controlled SCRs to avoid fault propagation The MGETM UpsilonTM STS transfer system implements controlled SCRs and monitors them continuously using a LEM current sensor to avoid any risk of fault propagation. This system (see fig. 4.94) is the means to: - Monitor status of each SCR. - Know whether it is conducting or not. - Detect faults (e.g. short-circuits). - Determine the direction of current flow. It is thus possible to control the SCRs and avoid exchange of current between the two sources (and consequently any risk of fault propagation). Transfer disabled if a fault occurs on the SCRs of the active static-switch Detection of a fault on the active static switch blocks transfer (see fig. 4.95). - The load remains on the conducting SS and transfer is disabled. - The opposite upstream switch is opened. Fig. 4.94. Transfer with controlled SCRs. APC by Schneider Electric 05/2009 edition ch. 4 – p. 87 MGETM UpsilonTM STS static transfer switch (cont.) Fig. 4.95. Conduction is maintained if a fault occurs on an SCR in the active SS. Improved power availability The availability of power in an installation depends essentially on: The availability of utility power; The autonomy and reliability of the sources (UPSs, engine-generator sets, etc.); The installation architecture and its level of redundancy. MGETM UpsilonTM STS lies at the heart of redundant architectures and improves availability through: Redundancy of sources of all types (UPSs, engine-generator sets, transformers); Numerous supply channels for loads, in conjunction with PDU modules (see fig. 4.92). The probability of faults occurring simultaneously on all the supply channels is virtually zero; Selection of the best source by monitoring eleven electrical parameters, including voltage levels and phase displacement. Simplified and secure maintenance MGETM UpsilonTM STS makes for maintenance that is: Simplified: rapid servicing is possible without interrupting the loads by manually transferring from one source to the other; Secure: a part of the installation can be totally isolated for servicing under deenergised conditions. It is also possible to carry out source operating tests using test loads; Planned: maintenance by manufacturers on the various installation components can be organised in advance. All these factors enhance power availability by reducing the MTTR. Reliability MGETM UpsilonTM STS design includes: Redundancy of the essential functions: - redundant power for the system control electronics; - independent power supply for each board; - double cooling system for the static switches (two heat sinks and two fans); Fault tolerance. This means that if an internal component fails, MGETM UpsilonTM STS shifts to the operating mode (transfer initiated or blocked) that best ensures the continuity of power to the load. An user alarm is issued. Segmenting and possible upgrades of installation power MGETM UpsilonTM STS is the means to segment the protected loads into zones that can be isolated from the rest of the installation, thus making for easier operation. This feature also makes it possible to increase installation power while continuing normal operation of the loads. APC by Schneider Electric 05/2009 edition ch. 4 – p. 88 MGETM UpsilonTM STS static transfer switch (cont.) Communication and easy operation The MGETM UpsilonTM STS communication interface is both user-friendly and intuitive. The names of the sources can be set by the user on the screen. An animated mimic panel clearly displays the various status conditions of the sources and the loads. The graphic, multi-lingual LCD display (16 languages: English, French, German, Dutch, Spanish, Italian, Portuguese, Swedish, Finnish, Russian, Polish, Turkish, Greek, Mandarin, Thai, Indonesian) provides easy, user-friendly access to the information screens. MGETM UpsilonTM STS is equipped with the following standard equipment: - 1 dry-contact communication card (6 relays 250 V, 2 A); - 1 JBus/Modbus communication card (RS232 or RS285); - 2 free slots for two additional cards. Small footprint MGETM UpsilonTM STS is available in two types of cabinets (high and low versions), depending on the ratings, offering minimum footprints. Footprint of 0.34 square metres (with Footprint of 0.59 square metres. clearances). Upsilon STS 30 - 60 - 100 -160 - 250 A. Upsilon STS 30 - 60 - 100 -160 - 250 - 400 - 630 A. Fig. 4.96. Two cabinet sizes offering small footprints. APC by Schneider Electric 05/2009 edition ch. 4 – p. 89 MGETM UpsilonTM STS static transfer switch (cont.) Diagram and functions Components and functions in MGETM UpsilonTM STS static transfer switches Standard ● Two three-phase static switches implementing IGBT technology ● Transfer with no transient cross-conduction using controlled SCRs. ● Control electronics for: - monitoring of all parameters (power sources, loads, static switches) - SCR control ● Three isolation switches ● Redundant power supplies ● Redundant cooling systems ● Triple detection system for overloads (current, thermal, temperature) ● Oversized neutral conductor ● Mimic panel for control and indications ● Two communication cards: - auxiliary relays - RS232 or RS485 JBus/Modbus card ● Two available slots ● Functions: - preferred source set by user - automatic or manual transfer between sources - reverse transfers - symmetrical operation - continuous monitoring of sources -selection of the best source based on user-set parameters for transfer conditions - access to measurements and alarms Optional ● Two additional communication cards: - relay card - RS485 JBus/Modbus card ● PDU in the upper part of the cabinet with 36 outgoing distribution circuit breakers Fig. 4.97. MGE APC by Schneider Electric TM Upsilon TM 05/2009 edition STS operating diagram. ch. 4 – p. 90 MGETM UpsilonTM STS static transfer switch (cont.) MGETM UpsilonTM STS characteristics Rated current (A) 30 60 Electrical input characteristics Voltage (source) Frequency Number of phases Type of connection Max. upstream short-circuit power Technical characteristics Overload Efficiency at In Withstand capacity for non-linear loads Transfer time Losses (W) (standard RL load, pf = 0.8, 100% rated load) Configuration Parameters Communication Standard Optional Dimensions, weights Low cabinet Height x width x depth (mm) Weight (kg) High cabinet Height x width x depth (mm) Weight (kg) Environment Noise level (dBA) as per ISO 3746 Degree of protection (as per IEC 529) Air throughput (m3/h) Storage temperature range Operating temperature range Altitude Standards Construction and safety EMC Harmonics Design, manufacturing Certification and marking APC by Schneider Electric 100 160 250 400 630 380 V (± 35%) - 400 V - 415 V (± 20%), three phase 50 or 60 Hz ± 10% 3 phases interrupted (3-pole STS) or 3 ph + N interrupted (4-pole STS) 3 or 4 wires + earth 35 kA 105% continuous, 110% for 15 minutes, 120% for 10 minutes, 135% for 5 minutes, 150% for 2 minutes, 200% for 20 seconds, 600% for 1 second, 2000% for 20 milliseconds 99% Fc < 3.5 5 ms 195 295 430 615 920 1420 2150 Phase displacement, overvoltage, undervoltage, overload, frequency, time for transfer back, powerbreak time LCD graphic display (backlit, multi-lingual) with menu for access to transfers, alarms, measurements, status conditions, history Animated mimic panel with 13 LEDs and buzzer 1 dry-contact communication card 1 RS232 or RS485 JBus communication card 2 available slots 11 isolated, changeover dry contacts for remote control RS485 JBus/Modbus link 6 remote controls 1400 x 610 x 560 193 no 211 1900 x 715 x 825 215 225 327 < 60 IP 215 350 1600 - 40° C to + 70° C dry heat 0 to 40° C continuous ≤ 1000 metres, derating required for higher altitudes IEC 60950-1 IEC 62040-1 IEC 62040-3 EN 50091-2 IEC 62040-2 / EN 62040-2 EMC directive 2004/108/EC IEC 61000-2-2 / EN 61000-2-2 IEC 61000-3-2/ EN 61000-3-2 IEC 61000-3-4 EN 61000-3-4 IEC 61000-3-5 EN 61000-3-5 ISO 14001 / ISO 9001 TÜV / CE / LCIE 05/2009 edition ch. 4 – p. 91 Source synchronisation module Presentation Source synchronisation upstream of an STS Synchronisation module ● Synchronisation of two sources upstream of an STS ● One of the sources must be controllable (MGETM GalaxyTM PW, 5000 , 7000 , 9000). Fig. 4.98. Synchronisation module. Applications A source synchronisation module maintains the voltages of two independent sources in phase. At least one of the two sources must be controllable, i.e. it must be an APC by Schneider Electric MGETM GalaxyTM PW, 5000, 7000 or 9000 UPS system (any type, i.e. single-unit, integrated parallel configuration or parallel configuration with centralised static switch cubicle) The second source may either be the utility, a UPS, a transformer or an enginegenerator set. A source synchronisation module increases the availability of power downstream of the STS (static transfer switch) units in that the synchronised upstream sources are always available for transfer. Configuration The synchronisation modules are used in conjunction with a set of UPSs and STS (static transfer switch) units to create high-availability configurations for internet applications as well as industrial and commercial processes. The modules ensure synchronisation of the output voltages for two or more independent sources, generally made up of UPSs, whatever the operating conditions, thus increasing the dependability of STS transfers. Fig. 4.99. Example of a high-availability configuration with synchronisation modules. Colour Light grey RAL 9002. For other colours, please contact us. APC by Schneider Electric 05/2009 edition ch. 4 – p. 92 Source synchronisation module (cont.) Suitable for different types of sources Modules can ensure synchronisation of many different types of sources (UPSs from other manufacturers, transformers, engine-generator sets, etc.) with a controllable TM TM source (MGE Galaxy PW, 5000 , 7000 or 9000 UPS). Main features Dependable transfer of the STSs and reliable operation Modules are very reliable, i.e. they can synchronise UPS voltages under all operating conditions, thus increasing the dependability of STS transfers and, consequently, the availability of power for loads. Small size and easy installation Their small size means that modules can be easily installed on a wall, near the UPS units. Components and functions in synchronisation modules Components Standard ● Synchronisation of two sources of which one TM TM must be controllable (MGE Galaxy PW, 5000 , 7000 or 9000 UPS) ● LED display on the module providing operating information ● Indication of module control provided on the UPS ● Two selectable operating modes: - "automatic source", preferable when both sources are controllable - "fixed source", when one of the sources cannot be controlled or when more than two sources must be synchronised ● Internal checks ensure high operating reliability of modules ● Synchronisation goes to standby mode if an internal fault occurs. An alarm is issued and indicated on the display ● IP 215 enclosure with lockable door Fig 4.100. Control panel. Characteristics Dimensions, weights Height (mm) Width (mm) Depth (mm) Weight (kg) Environment Degree of protection (as per IEC 529) Storage temperature range Operating temperature range Altitude Standards Construction and safety EMC Harmonics Design, manufacturing Certification and marking APC by Schneider Electric 500 400 200 IP 215 - 25° C to + 70° C dry heat 0 to 40° C continuous 1000 metres, derating required for higher altitudes IEC 60950-1 EN 50091-2 IEC 62040-2 / EN 62040-2 EMC directive 2004/108/EC IEC 61000-2-2 / EN 61000-2-2 IEC 61000-3-2/ EN 61000-3-2 IEC 61000-3-4 EN 61000-3-4 IEC 61000-3-5 EN 61000-3-5 ISO 14001 / ISO 9001 TÜV / CE / LCIE 05/2009 edition ch. 4 – p. 93 Chapter 5. Theoretical review Contents Supplying sensitive loads ..............................................5-2 Types of electrical disturbances ...........................................................5-2 Main disturbances in low-voltage electrical power................................5-3 UPSs.................................................................................5-4 The UPS solution .................................................................................5-4 UPS applications ..................................................................................5-5 Types of UPSs .................................................................5-7 Static or rotary UPS..............................................................................5-7 Types of static UPSs ............................................................................5-9 UPS components and operation....................................5-14 Components of a UPS..........................................................................5-14 Main characteristics of UPS components .............................................5-17 Summary diagram for main characteristics ..........................................5-22 UPS operating modes ..........................................................................5-23 UPS configurations...............................................................................5-24 Electromagnetic compatibility (EMC)............................5-26 Electromagnetic disturbances ..............................................................5-26 EMC standards and recommendations ................................................5-26 UPS standards.................................................................5-28 Scope and observance of standards ....................................................5-28 Main standards governing UPSs ..........................................................5-28 Energy storage ................................................................5-31 Possible technologies...........................................................................5-31 Batteries ...............................................................................................5-31 UPS / generator-set combination...................................5-35 Use of a generator................................................................................5-35 UPS / generator-set combination .........................................................5-35 Transient load conditions...............................................5-37 Review of inrush currents .....................................................................5-37 Harmonics........................................................................5-38 Harmonics ............................................................................................5-38 Characteristic harmonic values ............................................................5-40 Non-linear loads and PWM technology.........................5-43 Non-linear load performance of UPSs using PWM technology ............5-43 Comparison of different sources...........................................................5-46 Free-frequency chopping .....................................................................5-47 PFC rectifier.....................................................................5-49 APC by Schneider Electric 05/2009 edition ch. 5 - p. 1 Supplying sensitive loads Types of electrical disturbances Power distribution systems, both public and private, theoretically supply electrical equipment with a sinusoidal voltage of fixed amplitude and frequency (e.g. 400 volts rms, 50 Hz, on low-voltage systems). In real-life conditions however, utilities indicate the degree of fluctuation around the rated values. Standard EN 50160 defines the normal fluctuations in the LV supply voltage on European distribution systems as follows: Voltage +10% to -15% (average rms values over 10-minute intervals), of which 95% must be in the +10% range each week. Frequency +4 to 6% over one year with 1% for 99.5% of the time (synchronous connections in an interconnected system). Practically speaking, however, in addition to the indicated fluctuations, the voltage sine-wave is always distorted to some degree by various disturbances that occur on the system. See White Paper WP 18 “The Seven Types of Power Problems” See WP 18 Origins of disturbances Utility power Utility power can be disturbed or even cut by the following phenomena: Atmospheric phenomena affecting overhead lines or buried cables: - lightning which can produce a sudden voltage surge in the system, - frost which can accumulate on overhead lines and cause them to break, Accidents: - a branch falling on a line, which may produce a short-circuit or break the line, - cutting of a cable, for example during trench digging or other construction work, - a fault on the utility power system, Phase unbalance, Switching of protection or control devices in the utility power system, for load shedding or maintenance purposes. User equipment Some equipment can disturb the utility power system, e.g.: Industrial equipment: - motors, which can cause voltage drops due to inrush currents when starting, - equipment such as arc furnaces and welding machines, which can cause voltage drops and high-frequency interference, Power electronics equipment (switch-mode power supplies, variable speed drives, electronic ballasts, etc.), which often cause harmonics, Building facilities such as lifts which provoke inrush currents or fluorescent lighting which causes harmonics. Types of disturbances Disturbances that are due to the above causes are summed up in the following table, according to the definitions contained in standards EN 50160 and ANSI 1100-1992. APC by Schneider Electric 05/2009 edition ch. 5 - p. 2 Supplying sensitive loads (cont.) Disturbances Power outages Micro-outages Outages Voltage variations Voltage sags Overvoltage Characteristics Main causes Main consequences Total absence of voltage 10 ms. Atmospheric conditions, switching, faults, work on the utility. Faulty operation and loss of data (computer systems) or interrupted production (continuous processes). Total absence of voltage for more than one period: - short outage: 3 minutes (70% of outages last less than 1 s) - long outage: > 3 minutes Atmospheric conditions, switching, faults, incidents, line breaks, work on the utility. Depending on the duration, shutdown of machines and risks for people (e.g. lifts), loss of data (computer systems) or interrupted production (continuous processes). Reduction in the rms value of voltage to less than 90% of the rated value (but greater than 0%), with return to a value greater than 90% within 10 ms to 1 minute. Temporary increase to more than 10% over the rated voltage, for a duration of 10 ms to a few seconds. Atmospheric phenomena, load fluctuations, short-circuit on a neighbouring circuit. Shutdown of machines, malfunctions, damage to equipment and loss of data. - Quality of utility generators and transmission systems. - Interaction between generators and load fluctuations on the utility power system. - Switching on the utility power system. - Stopping of high-power loads (e.g. motors, capacitor banks). Peak in consumption, when the utility cannot meet demand and must reduce its voltage to limit power. - For computer systems: corruption of data, processing errors, system shutdown, stress on components. - Temperature rise and premature aging of equipment. Undervoltage Drop in voltage lasting from a few minutes to days. Voltage spike Sudden, major jump in voltage (e.g. 6 kV). Close lightning strikes, static discharges. Processing errors, corruption of data, system shutdown. Damage to computers, electronic boards. Voltage unbalance (in three-phase systems) Condition where the rms value of the phase voltages or the unbalances between phases are not equal. - Induction furnaces. - Unbalanced single-phase loads. - Temperature rise. - Disconnection of a phase. Instability in the frequency. Typically +5%, - 6% (average for ten-second time intervals). - Regulation of generators. - Irregular operation of generators. - Unstable frequency source. Flicker in lighting systems due to a drop in voltage and frequency (< 35 Hz). Welding machines, motors, arc furnaces, X-ray machines, lasers, capacitor banks. These variations exceed the tolerances of certain instruments and computer hardware (often ± 1%) and can therefore result in the loss or corruption of data. Physiological disturbances. Sudden, major and very short jump in voltage. Similar to a voltage spike. Atmospheric phenomena (lightning) and switching. < 1 s Amplitude < 1 to 2 kV at frequencies of several tens of MHz. > 1 s and 100 s Peak value 8 to 10 times higher than the rated value up to several MHz. > 100 s Peak value 5 to 6 times higher than the rated value up to several hundred MHz. Distortion of the current and voltage sine-waves due to the harmonic currents drawn by non-linear loads. The effect of harmonics above the 25th order is negligible. Electromagnetic or electrostatic conducted or radiated disturbances. The goal is to ensure low emission and high immunity levels. Starting of small inductive loads, repeated opening and closing of low-voltage relays and contactors. Faults (lightning) or high-voltage switching transmitted to the lowvoltage by electromagnetic coupling. Stopping of inductive loads or high-voltage faults transmitted to the low-voltage system by electromagnetic coupling. Electric machines with magnetic cores (motors, off-load transformers, etc.), switch-mode power supplies, arc furnaces, variable speed drives. Switching of electronic components (transistors, thyristors, diodes), electrostatic discharges. Frequency variations Frequency fluctuations Flicker Other disturbances HF transients Short duration Medium duration Long duration Harmonic distortion Electromagnetic compatibility (EMC) APC by Schneider Electric 05/2009 edition Shutdown of computer systems. Corruption or loss of data. Temperature rise. Premature ageing of equipment. Destruction of equipment, accelerated aging, breakdown of components or insulators. Oversizing of equipment, temperature rise, resonance phenomena with capacitors, destruction of equipment (transformers). Malfunctions of sensitive electronic devices. ch. 5 - p. 3 UPSs The UPS solution Modern economic activities are increasingly dependent on digital technologies which are very sensitive to electrical disturbances. As a result, many applications require a backed up supply of power to protect against the risk of disturbances in utility power: Industrial processes and their control/monitoring systems - risks of production losses, Airports and hospitals - risks for the safety of people, Information and communication technologies related to the internet - risks of processing shutdowns with very high hourly downtime costs due to the interruption in the exchange of vital data, required by global companies. UPSs A UPS (uninterruptible power system) is used to supply sensitive applications with secure power. A UPS is an electric device positioned between the utility and the sensitive loads that supplies voltage offering: High quality: the output sine-wave is free of any and all disturbances in utility power and within strict amplitude and frequency tolerances, High availability: the continuous supply of voltage, within the specified tolerances, is ensured by a backup supply of power. The backup supply is generally a battery that, if necessary, steps in without a break in the supply to replace utility power and provide the backup time required by the application. These characteristics make UPSs the ideal power supply for all sensitive applications because they ensure power quality and availability, whatever the state of utility power. Components of a UPS A UPS generally comprises the main components listed below. Rectifier/charger It draws utility power and produces a DC current to supply the inverter and charge or recharge the battery. Inverter It completely regenerates a high-quality voltage output sine-wave: Free of all utility-power disturbances, notably micro-outages, Within tolerances compatible with the requirements of sensitive electronic devices (e.g. tolerances in amplitude ± 0.5% and frequency ± 1%, compared to ± 10% and ± 5% in utility power systems, which correspond to improvement factors of 20 and 5, respectively. Note. The term inverter is sometimes used to designate a UPS, when in reality it is only a part of the UPS. Battery The battery provides sufficient operating backup time (6 minutes to a number of hours) by stepping in to replace utility power as needed. Static bypass The static bypass ensures no-break transfer of the load from the inverter to direct utility power and back. No-break transfer is carried out by a device implementing SCRs (sometimes called a static switch). The static bypass makes it possible to continue supplying the load even if an internal fault occurs or during maintenance on the rectifier/charger and inverter modules. It can also serve for transfers to call on the full power available upstream in the event of overloads (e.g. short circuits) exceeding UPS capacity. During operation on the static bypass, the load is supplied directly by utility power and is no longer protected (operation in downgraded mode). Maintenance bypass This bypass may be used to supply the load directly with utility power, without calling on the inverter or the static switch. Transfer to the maintenance bypass is user initiated with switches. By actuating the necessary switches, it is the means to isolate the static bypass and the inverter for maintenance, while continuing to supply the load in downgraded mode. APC by Schneider Electric 05/2009 edition ch. 5 - p. 4 UPSs (cont.) HV system HV/LV transformer Normal utility power (disturbances and system tolerances) UPS Non-sensitive loads Rectifier/ charger Battery Inverter Maintenance bypass Static bypass Reliable power (no disturbances, within strict tolerances and available due to battery backup power) Sensitive loads Fig. 5.1. The UPS solution. UPS applications APC by Schneider Electric UPSs are used for a wide range of applications requiring electrical power that is available at all times and not affected by disturbances on the utility power system. The table below presents a number of applications. For each, it indicates the sensitivity of the application to disturbances and the type of UPS that is suitable for protection. The applications requiring this type of installation are: Computer systems, Telecommunications, Industry and instruments, Other applications. The required UPS typologies are presented on page 9, "Types of static UPSs". They include static UPSs implementing the following typologies: Passive standby, Interaction with the distribution system, Double conversion. 05/2009 edition ch. 5 - p. 5 UPSs (cont.) UPS applications Application Computer systems Data centres Company networks Small networks and servers Stand-alone computers Telecommunications Telecommunications Protected devices Protection required against MicroOutages Voltage outages variations Frequency Other variations - Large bays for rack-mounted servers - Internet data centres - Sets of computers with terminals and peripheral devices (tape storage units, disk drives, etc.) - Networks made up of PCs or workstations, server networks (WAN, LAN) - PCs, workstations - Peripheral devices: printers, plotters, voice mail ***** ***** ***** ***** ***** Double conversion ***** ***** ***** ***** ***** Double conversion **** **** *** *** ** Interaction with the distribution system ** ** * * ** Passive standby - Digital PABXs ***** ***** ***** ***** ***** Double conversion *** ***** *** *** **** Double conversion **** ***** **** **** *** Double conversion *** **** *** *** *** Double conversion ** **** *** *** ** Double conversion Interaction with the distribution system **** **** **** ***** *** Double conversion Industry and instruments Industrial processes - Process control - PLCs - Numerical control systems - Control systems - Robot control/monitoring systems - Automatic machines Medical and laboratories - Instrumentation - Scanners (60 Hz) Industrial equipment - Machine-tools - Welding robots - Plastic-injection presses - Precise regulation devices (textile, paper, etc.) - Heating equipment for manufacture of semi-conductors, glass, pure materials Lighting systems - Public buildings (elevators, safety equipment) - Tunnels - Runway lighting in airports Other applications Special frequencies - Frequency conversion - Power supplies for aircraft (400 Hz) * low sensitivity to disturbances. ***** high sensitivity to disturbances. APC by Schneider Electric 05/2009 edition UPS type (see p. 8) ch. 5 - p. 6 Types of UPSs Static or rotary UPS See WP 92 Static or rotary UPS solutions There are two main types of UPSs (figure 5.2 and details in White Paper WP 92 "Comparison of Static and Rotary UPS") which basically differ in the way the UPS inverter function is implemented. Static solution These UPSs use only electronic components to perform the inverter function. A "static-inverter function" is obtained. Rotary solution These UPSs use rotary machines to perform the inverter function. A "rotary-inverter function" is obtained. These UPSs in fact combine a motor and a generator with a highly simplified static inverter. The inverter filters out utility-power disturbances and regulates only the frequency of its output voltage (generally in "square-wave" form) which supplies a regulated motor/generator set that is sometimes combined with a flywheel. The motor/generator set generates an output voltage sine-wave, taking the inverter output frequency as the reference. Fig. 5.2. Static and rotary UPSs. Comparison Rotary solution The arguments often put forward in favour of this solution are as follows: High generator short-circuit current on the order of 10 In (ten times the rated current) that makes setting of protection devices easier, 150% overload capacity (of the rated current) over a longer period (two minutes instead of one), Downstream installation galvanically isolated from upstream AC source due to the motor/generator set, Internal impedance providing high tolerance to the non-linear loads frequently encountered with the switch-mode power supplies used by computer systems. APC by Schneider Electric 05/2009 edition ch. 5 - p. 7 Types of UPSs (cont.) Static solution Compared to the advantages of rotary solutions The static UPSs from APC by Schneider Electric offer the advantages listed below. Operation in current-limiting mode (e.g. up to 2.33 In for MGE Galaxy 5000) with discrimination ensured for circuits rated up to In/2. These features, which are more than sufficient in practice, prevent the disadvantages of rotary systems: - overheating of cables, - the effects of an excessive short-circuit current and the corresponding voltage drop on sensitive devices, during the time taken by protective devices to clear the fault. 150% overload capacity (of the rated current) for one minute. The two-minute overload capacity is of no practical use because most overloads are very short (less than one second, e.g. in-rush currents of motors, transformers and power electronics). Galvanic isolation, when required, by means of an isolating transformer. Double-conversion operation which completely isolates the load from utility power and regenerates the output voltage with precise regulation of the voltage amplitude and the frequency. Very low internal impedance for higher performance with non-linear loads due to the use of power-transistor technologies. Other advantages Static solutions provide many other advantages as well, due to power-transistor technology combined with a PWM chopping technique. Simplified overall design, with a reduction in the number of parts and connections, and in the number of possible causes of failure. Capacity to react instantaneously to utility-power amplitude and frequency fluctuations by means of microprocessor-controlled switching regulation based on digital sampling techniques. The voltage amplitude returns to regulated conditions (± 0.5% or ± 1% depending on the model) in less than 10 milliseconds for load step changes up to 100%. Within the indicated time interval, such a load step change produces a load voltage variation of less than for example ± 2% for MGE Galaxy PW and Galaxy 5000. High, constant efficiency whatever the percent load, which is a major advantage for redundant UPS units with low percent loads. A static UPS unit with a 50% load maintains high efficiency (94%), whereas the efficiency of a rotary UPS drops to the 88-90% range (typical value), which directly impacts on operating costs. Redundant configurations providing high availability in the framework of ultrareliable supply systems (e.g. for data centres). Possible integration in redundant architectures with separate functions that facilitate maintenance by isolating parts of the installation. Rotary systems integrate the UPS, the backup power and the generator as a single component, thus making it impossible to separate the functions. No single points of failure. Rotary systems incorporating flywheels depend on the capacity of the motor to start quickly (typically in less than 12 seconds). This means the motor must be in perfect condition and rigorously maintained. If it does not start, there is no time to shut down the critical loads in an orderly manner. Consider also the following non-negligible advantages: reduced dimensions and weight, no wear on rotating parts, hence easier and faster maintenance. For example, rotary systems require checks on the alignment of the rotating parts and the replacement of the bearings after 2 to 6 years is a major operation (lifting equipment, heating and cooling of the bearings during the replacement). Conclusion Given the advantages presented above, static UPSs are used in the vast majority of cases, and for high-power applications in particular. In the following pages, the term uninterruptible power supply (UPS) is taken to mean the static solution. APC by Schneider Electric 05/2009 edition ch. 5 - p. 8 Types of UPSs (cont.) Types of static UPSs Standards UPSs Due to the vast increase in the number of sensitive loads, the term "UPS" now includes devices ranging from a few hundred VA for desktop computers up to several MVA for data centres and telecommunications sites. At the same time, different typologies have been developed and the names used for the products on the market are not always clear (or even misleading) for end users. That is why the IEC (International Electrotechnical Commission) established standards governing the types of UPSs and the techniques used to measure their performance levels, and those criteria were adopted by Cenelec (European standardisation commission). Standard IEC 62040-3 and its European equivalent EN 62040-3 define three standard types (topologies) of UPS and their performance levels. UPS technologies include: ● Passive standby, ● Line interactive, ● Double conversion. AC input power These definitions concern UPS operation with respect to the power source including the distribution system upstream of the UPS. The standards define the following terms: Primary power: power normally continuously available which is usually supplied by an electrical utility company, but sometimes by the user's own generation, Standby power: power intended to replace the primary power in the event of primary-power failure, Practically speaking, a UPS has one or two inputs: Normal AC input (or Mains 1), supplied by primary power, Bypass AC input (or Mains 2), supplied by standby power (generally speaking via a separate cable from the same main low-voltage switchboard (MLVS). UPS operating in passive-standby mode The UPS is installed in parallel to the utility and backs it up. The battery is charged by a charger that is separate from the inverter. Operating principle Normal mode - The inverter operates in passive standby mode. - The load is supplied by utility power via a filter which eliminates certain disturbances and provides some degree of voltage regulation. - The standards do not mention this filter and speak simply of a "UPS switch". They also indicate that "additional devices may be incorporated to provide power conditioning, e.g. ferroresonant transformer or automatic tap-changing transformer". Battery backup mode - When the AC input voltage is outside specified tolerances for the UPS or the utility power fails, the inverter and the battery step in to ensure a continuous supply of power to the load following a very short transfer time (generally less than 10 ms). The standards do not stipulate a time, but do indicate that "the load [is] transferred to the inverter directly or via the UPS switch (which may be electronic or electromechanical)". - The UPS continues to operate on battery power until the end of battery backup time or utility power returns to normal, which provokes transfer of the load back to the AC input (normal mode). APC by Schneider Electric 05/2009 edition ch. 5 - p. 9 Types of UPSs (cont.) Fig. 5.3. UPS operating in passive-standby mode. Advantages Simple diagram. Reduced cost. Disadvantages No real isolation of the load with respect to the upstream distribution system. Transfer time. It operates without a real static switch, so a certain time is required to transfer the load to the inverter. This time is acceptable for certain individual applications, but incompatible with the performance required by more sophisticated, sensitive systems (large computer centres, telephone exchanges, etc.). No regulation of the output frequency, which is simply that of the utility power. Usage This configuration is in fact a compromise between an acceptable level of protection against disturbances and cost. The mentioned disadvantages mean that, practically speaking, this type of UPS can be used only for low power ratings (< 2 kVA) and cannot be used as a frequency converter. UPS operating in line-interactive mode The inverter is connected in parallel with the AC input in a standby configuration, and also charges the battery. It thus interacts (reversible operation) with the AC-input source. Operating principle Normal mode The load is supplied with conditioned power via a parallel connection of the AC input and the inverter. As long as the utility power is within tolerances, the inverter regulates fluctuations in the input voltage. Otherwise (reversible operation), it charges the battery. The output frequency depends on the AC-input frequency. Battery backup mode - When the AC input voltage is outside specified tolerances for the UPS or the utility power fails, the inverter and the battery step in to ensure a continuous supply of power to the load. The power switch (e.g. static switch) also disconnects the AC input to prevent power from the inverter from flowing upstream. - The UPS continues to operate on battery power until the end of battery backup time or utility power returns to normal, which provokes transfer of the load back to the AC input (normal mode). APC by Schneider Electric 05/2009 edition ch. 5 - p. 10 Types of UPSs (cont.) Bypass mode This type of UPS may be equipped with a bypass. If one of the UPS functions fails, the load can be transferred to the bypass AC input via the maintenance bypass. Fig. 5.4. UPS operating in line-interactive mode. Advantages The cost can be less than that for a double-conversion UPS with an equivalent power rating because the inverter does not operate continuously. Disadvantages No real isolation of the load with respect to the upstream distribution system, thus: - sensitivity to variations in the utility voltage and frequent demands placed on the inverter, - influence of downstream non-linear loads on the upstream input voltage. No regulation of the output frequency, which is simply that of the utility power. Mediocre conditioning of the output voltage because the inverter is not installed in series with the AC input. The standard speaks of "conditioned power" given the parallel connection of the AC input and the inverter. Conditioning is, however, limited by the sensitivity to upstream and downstream voltage fluctuations and the reversible operating mode of the inverter. Efficiency depends on: - the type of load. With non-linear loads, the current drawn comprises harmonics that alter the fundamental. The harmonic currents are supplied by the reversible inverter which regulates the voltage and efficiency is sharply reduced. - the percent load. The power required to charge the battery becomes increasingly significant as the percent load decreases. A single point of failure exists due to the absence of a static bypass, i.e. if a malfunction occurs, the UPS shuts down. Usage This configuration is not well suited to regulation of sensitive loads in the medium to high-power range because frequency regulation is not possible. For this reason, it is rarely used other than for low power ratings. APC by Schneider Electric 05/2009 edition ch. 5 - p. 11 Types of UPSs (cont.) Double-conversion UPSs The inverter is connected in series between the AC input and the application. The power supplied to the load continuously flows through the inverter. Operating principle Normal mode During normal operation, all the power supplied to the load passes through the rectifier/charger and inverter which together perform a double conversion (AC-DCAC), hence the name. The voltage is continuously regenerated and regulated. Battery backup mode - When the AC-input voltage is outside specified tolerances for the UPS or the utility power fails, the inverter and the battery step in to ensure a continuous supply of power to the load. - The UPS continues to operate on battery power until the end of battery backup time or utility power returns to normal, which provokes transfer of the load back to the AC input (normal mode). Bypass mode This type of UPS comprises a static bypass (sometimes called a static switch) that ensures no-break transfer of the load from the inverter to direct utility power and back. The load is transferred to the static bypass in the event of the following: - UPS failure, - load-current transients (inrush or fault currents), - overloads, - end of battery backup time. The presence of a static bypass assumes that the input and output frequencies are identical, which means it cannot be used as a frequency converter. If the voltage levels are not the same, a bypass transformer is required. The UPS is synchronised with the bypass AC input to ensure no-break transfers from the inverter to the bypass line. Note. Another bypass line, often called the maintenance bypass, is available for maintenance purposes. It is closed by a manual switch. Fig. 5.5. Double-conversion UPSs. APC by Schneider Electric 05/2009 edition ch. 5 - p. 12 Types of UPSs (cont.) Advantages Complete regeneration of the output power, whether it comes from the utility or the battery. Total isolation of the load from the distribution system and its disturbances. Very wide input-voltage range, yet precise regulation of the output voltage. Independence of the input and output frequencies, thus ensuring an output frequency within strict tolerances. Capacity to operate as a frequency converter (if planned as such), by disabling the static switch. Much higher performance levels under steady-state and transient conditions. Instantaneous shift to battery backup mode if utility power fails. No-break transfer to a bypass line (bypass mode). Manual bypass (generally standard) to facilitate maintenance. Disadvantages Higher price, but compensated by the many advantages. Usage This configuration is the most complete in terms of load protection, regulation possibilities and performance levels. It notably ensures independence of the output voltage and frequency with respect to the input voltage and frequency. Its many advantages mean that it is virtually the only configuration used for medium and high power ratings (from 10 kVA upwards). Conclusion Double-conversion UPSs represent the vast majority of the medium to highpower systems sold (95% starting from a few kVA and 98% for 10 kVA and higher). This is due to their numerous strong points in meeting the needs of sensitive loads at these power ratings and is largely the result of the inverter positioned in series with the AC input. What is more, they have very few weak points except their high cost that is required to offer a level of performance that is often indispensable given the critical nature of the protected loads. A further weak point is slightly higher losses (a few percent). In the power ranges under consideration, the other technologies are marginal, in spite of a significantly lower cost. They have the disadvantages listed below. No voltage regulation for passive-standby UPSs. No frequency regulation for passive-standby UPSs and line-interactive UPSs. Mediocre isolation (often a surge arrestor) from the AC input due to the parallel configuration of the inverter. Conclusion For low power ratings (< 2 kVA), the three standardised technologies coexist. It is the cost effectiveness of the protection functions with respect to the requirements of the loads and the risks run (for people, production, etc.) that determines selection of one of the three typologies. Double-conversion UPSs are used almost exclusively for higher ratings. APC by Schneider Electric 05/2009 edition ch. 5 - p. 13 UPS components and operation Components of a UPS The information presented below concerns double-conversion UPSs, the technology most commonly used by APC by Schneider Electric for power ratings greater than 10 kVA. General diagram of a UPS The various items in the diagram below have been assigned numbers that correspond to the sections on the following pages. Fig. 5.6. Components of a UPS. Power sources and UPS inputs Practically speaking, a UPS has one or two inputs: Normal AC input (or Mains 1), supplied by primary power, Bypass AC input (or Mains 2), supplied by standby power (generally speaking via a separate cable from the same main low-voltage switchboard (MLVS). AC sources, see Ch. 5 p. 9. UPS connection to both the primary and standby-power sources (UPS inputs supplied by two separate circuits from the MLVS) is recommended because overall system reliability is increased. However, if two separate circuits from the MLVS are not available, it is possible to have both AC inputs (normal and bypass) supplied by primary power (second cable). Management of transfers between the two input lines is organised as follows. The UPS synchronises the inverter output voltage with that of the bypass line as long as the latter is within tolerances. It is thus possible, if necessary, for the static switch to transfer the load to the bypass AC input, without a break (because the two voltages are synchronised and in phase) or disturbances (because the standby power is within tolerances) for the load. When standby power is not within tolerances, the inverter desynchronises and transfer is disabled. It can, however, by carried out manually. APC by Schneider Electric 05/2009 edition ch. 5 - p. 14 UPS components and operation (cont.) Components of a UPS Rectifier/charger (1) Transforms the AC power from the primary-power source into DC voltage and current used to: Supply the inverter, Charge and float charge the battery. Inverter (2) Using the DC power supplied by the: Rectifier during normal operation, Battery during autonomous operation, the inverter completely regenerates a sinusoidal output signal, within strict amplitude and frequency tolerances. Battery (3) Makes the UPS autonomous with respect to the utility in the event of: A utility outage, Utility-power characteristics outside specified tolerances for the UPS. Battery backup times range from 6 to 30 minutes as standard and can be extended on request. Depending on the duration of the backup time, the battery is housed in the UPS cabinet or in a separate cabinet. Static bypass (4) A static switch is used to transfer the load from the inverter to the bypass without any interruption* in the supply of power to the load (no break because the transfer is performed by electronic rather than mechanical components). The switch is possible when the frequencies upstream and downstream of the UPS are identical. Transfer takes place automatically for any of the following reasons: Voluntary shutdown of the UPS, An overload exceeding the limiting capacity of the inverter (this transfer can be disabled), An internal fault. It can also be carried out manually. * No-break transfer is possible when the voltages at the inverter output and on the bypass AC input are synchronised. The UPS maintains synchronisation as long as the standby power is within tolerances. Manual bypass (5) A manual switch is used to transfer the load to the bypass for maintenance purposes. The switch is possible when the frequencies upstream and downstream of the UPS are identical. The shift to manual-bypass mode is carried out using manual switches. Manual switches (6, 7, 8) These devices isolate the rectifier/charger and inverter modules and/or the bypass line for servicing or maintenance. Battery circuit breaker (9) The battery circuit breaker protects the battery against excessive discharge, and the rectifier/charger and inverter against a battery short-circuit. Upstream isolating transformer (10) (optional equipment) Provides UPS input/output isolation when the downstream installation is supplied via the bypass. It is particularly useful when the upstream and downstream system earthing arrangements are different. May be installed in the UPS cabinet in the MGE Galaxy PW range. Voltage-matching transformer (11) (optional equipment) Adapts the voltage to the desired value. APC by Schneider Electric 05/2009 edition ch. 5 - p. 15 UPS components and operation (cont.) Filters (12) (optional equipment) Upstream of the rectifier/charger, when it is of the thyristor-based Graetz bridge type (the case for MGE Galaxy PW and 9000 UPSs), a harmonic filter (see ch. 1 p. 24) reduces the current harmonics resulting from the switching of the rectifier thyristors. This reduces the voltage distortion on the upstream busbars resulting from the flow of harmonic currents (the level required is generally <5%). What is more, these UPSs from APC by Schneider Electric are equipped with an oversized neutral conductor installed as standard to overcome the consequences of third-order harmonics and their multiples which flow in the neutral conductor. All the other UPSs of the MGE Galaxy and Symmetra ranges are equipped with a PFC-type rectifier that eliminates the need for a filter (see ch. 1 p. 24). Downstream, UPSs implementing new PWM-chopping techniques may be directly connected to non-linear loads. This technique makes it possible for UPSs from APC by Schneider Electric to maintain the THDU below 3%. Built-in communication (13) (14) In addition to the need for a user-friendly human/machine interface for effective monitoring of UPS operation, it is today increasingly important for UPSs to communicate with their electrical and computing environment (supervision systems, building management systems (BMS), computer management systems, etc.). UPSs from APC by Schneider Electric are designed with built-in capacity for total communication and include: A user-friendly human/machine interface (HMI) with an advanced graphic display and mimic panel. The interface is built up around self-monitoring and self-diagnostic systems that continuously indicate the status of the various UPS components, in particular the batteries. For example, for the MGE Galaxy ranges: - the Digibat system continuously monitors the status of the battery with full battery management features, - the B2000 or Cellwatch battery-monitoring system immediately detects and locates battery faults and provides predictive monitoring. For the Symmetra ranges: - The rack-mountable (1U) APC battery management system, accessible via a web browser, combines battery monitoring and testing with individual boost charging for peak battery performance. A large selection of communication cards compatible with market standards: - Network Management Card (Ethernet) - Modbus – Jbus card (RS232 & RS485) - Relay card (dry contacts) for indications - Teleservice modem card These cards can be used to implement supervision, notification, controlled shutdown and Teleservice functions. Human-machine interface and Communication: see Ch. 1 p. 49. Upstream and/or downstream distribution and protection devices (15) (16) (optional equipment) The UPS can be supplied with the following equipment: Upstream LV circuit-breakers for the AC inputs (normal and bypass), Upstream LV switchboard with circuit-breaker protection for the AC inputs (normal and bypass), Downstream LV switchboard with circuit-breaker protection for the different outgoing circuits. APC by Schneider Electric can offer a selection of UPSs and protection devices that are perfectly coordinated in terms of ratings and performance. Complete solutions APC by Schneider Electric can provide complete solutions comprising all the components listed above, including air-conditioning solutions for data centers, in conjunction with Schneider Electric. For users, the result is a single partner and an installation that offers optimum performance and reliability. APC by Schneider Electric 05/2009 edition ch. 5 - p. 16 UPS components and operation (cont.) Main characteristics of UPS components These characteristics are based on the main technical specifications presented in the IEC 62040-3 / EN 62040-3 standards on UPS performance requirements. Certain terms used here differ from the common jargon and a number of new features have not yet been assimilated by manufacturers. New terms or characteristics used by the standard are indicated between parentheses and preceded by an asterisk. For example, the title of a section "input current during battery float charging", a commonly used term, is followed by (*rated input current), the term used in the standard. Note that a number of numerical values are indicated as examples. They are, for the most part, drawn from the technical characteristics of the corresponding UPSs, indicated in chapter 4, or indicated simply for the purposes of the example. AC input power Number of phases and system earthing arrangement The AC-input supply (primary power) is three-phase + neutral. Single-phase inputs are not used for the power levels dealt with here. The system earthing arrangement is generally imposed by standards (IT, TT, TNS or TNC). Normal AC input The normal AC input is supplied with utility power for the rectifier/charger, within the specified tolerances. Example: 400 V rms ± 15% at a frequency of 50 or 60 Hz ± 5%, three-phase. Bypass AC input The bypass AC input is supplied with standby power. Practically speaking, this a cable connected to a utility feeder in the MLVS other than the one supplying the normal AC input. In general, it supplies voltage with the same characteristics as that of the primary power. Example: 400 V rms ± 15% at a frequency of 50 or 60 Hz ± 5%, and a short-circuit current Isc2 = 12.5 kA. The short-circuit current is important information for the downstream protection devices in the event of operation via the static or maintenance bypass. Supply of separate primary and standby power is recommended because it increases overall system reliability, but is not mandatory. However, if two separate circuits from the MLVS are not available, it is possible to have both AC inputs (normal and bypass) supplied by primary power (second cable). Rectifier/charger Floating voltage This is the voltage supplied by the rectifier/charger which keeps the battery fully charged. It depends on the batteries used and the manufacturer's recommendations. Input current during battery float charging (* rated input current) This is the current, under normal operating conditions, required to supply the inverter at its rated power while float charging the battery. Example: for a 100 kVA MGE Galaxy PW with a battery backup time of 10 minutes, this current is I input float = 166 A while float charging the battery. Input current during battery charging This corresponds to the current required to supply the inverter at its rated power while charging the battery. It is consequently higher than the previous current and is used to size the charger input cables. Example: for the same UPS as above, the input current is I input float = 182 A, i.e. higher than above because it is necessary to charge the battery. APC by Schneider Electric 05/2009 edition ch. 5 - p. 17 UPS components and operation (cont.) Maximum input current This is the input current with the UPS operating under worst-case conditions of permitted overload, with the battery discharged. It is higher than the above input current during battery charging (due to the overload current) but is limited in time (as is the overload). Example: for the same UPS as above, the MGE Galaxy PW can accept a 25% overload for ten minutes and a 50% overload for one minute. In the worst-case situation with the battery charging, the input current can reach: I input max. = 182 A x 1.25 = 227.5 A for ten minutes, I input max. = 182 A x 1.5 = 273 A for one minute. Beyond the above limits, the UPS initiates no-break transfer of the load to the bypass line and automatically transfers back when the overload has ended or been cleared by the corresponding protection devices. Battery (* energy storage means) Type A battery is characterised by its type (vented or sealed lead acid, or nickel/cadmium) and how it is installed. APC by Schneider Electric proposes sealed lead-acid batteries mounted in cabinets. Service life This is defined as the operating period, under normal usage conditions, for which the battery supplies at least 50% of the initial backup time. For example, MGE Galaxy PW is supplied as standard with sealed lead-acid batteries with a service life of ten years or more. This type of battery, rated for 30 minutes of backup time, will contractually supply only 15 minutes at the end of the specified service life. It may supply more if it has been used under optimum conditions (notably concerning the temperature). However, it is contractually guaranteed not to supply less, unless used improperly. Operating modes The battery may be: Charging. It draws a charge current (I1 charge) supplied by the rectifier/charger. Float charging. The battery draws a low, so-called floating current (I1 floating), supplied by the rectifier/charger, which maintains its charge by compensating for open-circuit losses. Discharging. The battery supplies the inverter until its shutdown voltage is reached. When this voltage, set by the battery manufacturer, is reached, the battery is automatically disconnected (UPSs from APC by Schneider Electric) to avoid damage by deep discharge. Rated voltage This is the DC output voltage that the battery supplies to the inverter. Example: 450 V DC for the MGE Galaxy PW range. Capacity Battery capacity is expressed in ampere/hours. Example: for a 100 kVA MGE Galaxy PW equipped with a battery offering ten minutes of backup time and a service life of five years, the capacity is 85 A/h. Number of cells Number of single battery cells making up the entire battery string. Example: the battery of a 100 kVA MGE Galaxy PW comprises, for a given type of battery, 33 cells providing 13.6 V each, for a backup time of ten minutes. Floating voltage This is the DC voltage used to maintain the battery charge, supplied by the rectifier/charger. Example: for a MGE Galaxy PW, the floating voltage is between 423 and 463 V DC. APC by Schneider Electric 05/2009 edition ch. 5 - p. 18 UPS components and operation (cont.) Backup time (* stored energy time) This is the time, specified at the beginning of the battery service life, that the battery can supply the inverter operating at full rated load, in the absence of the AC-input supply. Example: MGE Galaxy PW offers as standard backup times of 8, 10, 15, 20, 30 and 60 minutes. This time depends on the UPS percent load. For a UPS operating at full rated load (100% of rated power), the end of the battery backup time is reached when the battery voltage drops to the shutdown voltage specified by the manufacturer. This provokes automatic shutdown of UPSs from APC by Schneider Electric. For a UPS operating at a lower percent load (e.g. 75%), the actual backup time may be longer. However, it always ends when the battery shutdown voltage is reached. Recharge time (* rated restored energy time) This is the time required by the battery to recover 80% of its backup time (90% of its capacity), starting from the battery shutdown voltage. The rectifier/charger supplies the power. Example: for a MGE Galaxy PW UPS, the recharge time is eight to ten hours, depending on the battery and the backup time. Note that the probability of the battery being called on to supply power twice within such a short period is low. This means the indicated recharge time is representative of actual performance. Maximum battery current (Ib) When discharging, the battery supplies the inverter with a current Ib which reaches its maximum value at the end of discharging. This value determines battery protection and cable dimensions. Example: for a 100 kVA MGE Galaxy PW, this current is Ib max = 257 A. Inverter Rated power (Sn) (* rated output apparent power) This is the maximum apparent power Sn (kVA) that the inverter can deliver to a linear load at a power factor of 0.8, during normal operation under steady-state conditions. The standards also define this parameter for operation on battery power. Theoretically speaking, it is the same if the battery is correctly sized. Example: a MGE Galaxy PW with a rated power (Sn) of 100 kVA. Active output power (Pa) (* rated output active power for linear or reference non-linear load) This is the active power Pa (kW) corresponding to the apparent output power Sn (kVA), under the measurement conditions mentioned above. This value may also be indicated for a standardised reference non-linear load. Example: the previous UPS, a MGE Galaxy PW with a rated power of 100 kVA supplies an active power of Pa = Sn x 0.8 = 80 kW. Rated current (In) This is the current corresponding to the rated power. Example: again for a 100 kVA MGE Galaxy PW UPS and an output voltage of 400 V, this current is: Sn 100000 In = 144.3 A = 400 x 1732 , Un 3 APC by Schneider Electric 05/2009 edition ch. 5 - p. 19 UPS components and operation (cont.) Apparent load power (Su) and percent load This is the apparent power Sn (kVA) actually supplied by the inverter to the load, under the selected operating conditions. This value is a fraction of the rated power, depending on the percent load. .Su Sn. and .Tc = Percent load (%) = Su / Sn.. Example: for the UPS mentioned above, if the inverter supplies 3/4 of its rated power (75% load), it delivers an apparent power of 75 kVA, which under standard operating conditions (PF = 0.8) corresponds to an active load power of Pa = Su x PF = 75 x 0.8 = 60 kW. Load current (Iu) This is the current corresponding to the load power, that is, to the percent load in question. It is calculated from Pu as for the rated current, where the voltage is the rated voltage Un (value regulated by the inverter). Example: for the UPS mentioned above (75% load) 75000 Su Iu = = 108.2 A 400 x 1732 , Un 3 which is the same as: .Iu = In x Tc. = 144.3 x 0.75 = 108.2 A Efficiency () This is the ratio of active power Pu (kW) supplied by the UPS to the load to the power Pin (kW) that it draws at its input, either by the rectifier or from the battery. .= Pu / Pin. For most UPSs, efficiency is optimum at full rated load and drops sharply with lower percent loads. Due to their low output impedance and no-load losses, the efficiency of MGE Galaxy UPSs is virtually stable for loads from 25 to 100%. The MGE Galaxy PW range offers efficiency greater than 90% starting at 25% load, up to 93% at full rated load, as well as an ECO mode which increases efficiency by 4%, i.e. up to 97%. Practically speaking, for MGE Galaxy UPSs, an efficiency value of 0.93 can be used for all input-power calculations for loads from 30 to 100%. Example: for a 100 kVA MGE Galaxy PW at 75% load, 0.93 efficiency corresponds to a UPS active input power of Pin = Pu / = 60/0.93 = 64.5 kW. Output voltage Un Number of phases The output can be three-phase (3ph-3ph UPS) or single-phase (3ph-1ph UPS), depending on the situation. Note that the upstream and downstream system earthing arrangements may be different. Rated output voltage In general, it is the same as that of the AC input. However, a voltage-matching transformer may be installed. Static characteristics These are the tolerances (maximum permissible variations) for the amplitude and frequency of the output voltage under steady-state conditions. Stricter than those applying to utility power, they are measured for normal operation on AC-input power and for operation in battery backup mode. Output voltage variation The amplitude tolerance is expressed as a percentage of the nominal rms value and may be adjustable. Example: for a MGE Galaxy PW, the voltage 400 V rms ± 1% may be adjusted to ± 3%. The standards also stipulate a rated peak output voltage and the tolerance with respect to the rated value. Output frequency variation The tolerance is expressed as a percentage of the rated frequency. Example: for a MGE Galaxy PW, 50 or 60 Hz ± 0.1% during normal operation on primary power and ± 0.5% in battery backup mode. APC by Schneider Electric 05/2009 edition ch. 5 - p. 20 UPS components and operation (cont.) Frequency synchronisation with primary power The inverter supplies an output voltage within the above tolerances, regardless of the disturbances affecting the upstream power. To that end, the UPS: Monitors the voltage parameters (amplitude, frequency, phase) for the primarypower source to determine whether they are within specified tolerances, Reacts to any drift in parameters so as to: - readjust the inverter (phase and frequency) to the standby power, as long as the drift remains within tolerances, in view of load transfer, if necessary, - transfer the load to battery power as soon as the drift goes outside tolerances. The new IGBT and PWM chopping technologies used in UPSs from APC by Schneider Electric allow an excellent adaptation to these variations. Example: for MGE Galaxy PW UPSs, the maximum variation in frequency corresponding to the tolerance is 50 Hz x 0.5% = 0.25 Hz. Frequency synchronisation with bypass AC power is possible from 0.25 to 2 Hz, in 0.25 Hz steps. Practically speaking, this signifies that frequency variations may be monitored at dF/dt = 0.25 Hz/s and readjustment carried out within 0.25 to 1 second. Dynamic characteristics These are the tolerances under transient load conditions. MGE Galaxy PW UPSs are capable of withstanding the following conditions. Load unbalance For unbalance in the load voltage (phase-to-neutral or phase-to-phase) of: - 30%, the output voltage variation is less than 0.1%, - 100% (one phase at Pn and the others at 0), the output voltage does not vary more than 0.2%. Load step changes (voltage transients) For load steps from 0 to 100% or from 100 to 0% of the rated load, the voltage does not vary more than: ± 2% on utility power; + 2% to -4 % on battery power. Overload and short-circuit capacity Overloads - 1.1 In for 2 hours, - 1.5 In for 1 minute, with no change in the output tolerances. Short-circuits Beyond 1.65 In, MGE Galaxy PW inverters operate in current-limiting mode up to 2.33 In for 1 second, corresponding to: I peak max. = 2 x 1.65 In = 2.33 In. Beyond this value, the inverter transfers the load to standby power or performs a static shutdown (self-protection feature). Total output-voltage distortion UPSs must guarantee performance levels for all types of loads, including non-linear loads. Example: MGE Galaxy PW UPSs limit the voltage total harmonic distortion (THDU) in output power to the following levels for: 100% linear loads: - THDU ph/ph < 1.5 %, - THDU ph/N < 2%, 100% non-linear loads: - THDU ph/ph < 2 %, - THDU ph/N < 3%. MGE Galaxy PW UPSs operate in compliance with the specified characteristics for all types of loads. General note. The standard specifies certain of the previously mentioned performance levels for output power during normal operation and operation on battery power. In general, they are identical. APC by Schneider Electric 05/2009 edition ch. 5 - p. 21 UPS components and operation (cont.) Summary diagram for main characteristics Fig. 5.7. Diagram showing the main characteristics (see the list below). Normal AC input ● Voltage Un + 10% to - 15% ● Frequency f + 4% to - 6% Bypass AC input ● Voltage Un + 10% to - 15% ● Frequency f + 4% to - 6% ● Short-circuit current Isc2 (withstand capacity of the static bypass) Rectifier/charger ● Floating voltage ● Input currents - rated (battery float charging) - maximum (battery charging) Battery ● Backup time: standard 5, 6, 8, 10, 15, 20, 30, 60 minutes, longer times on request) ● Service life: 10 years or longer ● Maximum current Ib max. Inverter ● Apparent output power: - rated: Sn (kVA) - load power: Su (kVA) = Sn x Tc% ● UPS percent load Tc% = Su / Sn ● Active output power: - rated: Pn (kW) = Sn (kVA) x 0.8 - load power: Pu (kW) = Su (kVA) x PF = Sn x Tc% x PF = Un Iu PF ● Efficiency: Pu / Pn = 93% (97% in ECO mode). ● Static characteristics (output-voltage tolerances under steady-state conditions) - amplitude: Un ± 1% adjustable to ± 3% - frequency: f ± 1% during normal operation, f ± 0.5% in battery backup mode - inverter output voltage synchronised (frequency and phase) with that of the standby power as long as the latter is within tolerances. ● Dynamic characteristics (tolerances under transient conditions) - maximum voltage and frequency variations for load step changes from 0% to 100% or 100% to 0%: Un ± 2%, f ± 0.5% ● Output voltage distortion - 100% non-linear loads THDU < 2% ● Overload and short circuit capacity: - overloads: 1.5 In for 1 minute - short-circuits: current limiting to 2.33 In for 1 second Load ● Load current (Iu) ● Power factor PF APC by Schneider Electric 05/2009 edition ch. 5 - p. 22 UPS components and operation (cont.) UPS operating modes Normal mode (on utility power, see fig. 5.8 on left-hand side) The UPS draws the AC utility power required to operate via the rectifier/charger which provides DC current. Part of the utility power drawn is used to charge or float charge the battery: I1 floating, if the battery is already fully charged, I1 charge if the battery is not fully charged (i.e. charging following a recent discharge). The remaining current is supplied to the inverter with generates an output-voltage sine-wave within the specified amplitude and frequency tolerances. Battery backup mode (on battery power, see fig. 5.8 on right-hand side) The battery steps in to replace primary power and supplies the power required by the inverter for the load, with the same tolerances as in normal mode. This takes place through immediate transfer (the battery is parallel connected) in the event of: Normal AC-input failure (utility-power outage), Normal AC input outside tolerances (degradation of utility-power voltage). Normal mode. Fig. 5.8. Normal mode and battery backup mode. Battery backup mode. Bypass mode (on static-bypass line, see fig. 5.9 on left-hand side) A static switch (SS) ensures no-break transfer of the load to the bypass AC input for direct supply of the load by standby power. Transfer is automatic in the event of: An overload downstream of the UPS exceeding its overload capacity, An internal fault in the rectifier/charger and inverter modules. Transfer always takes place for internal faults, but otherwise is possible only if the voltage of the standby power is within tolerances and in phase with the inverter. To that end: The UPS synchronises the inverter output voltage with that of the bypass line as long as the latter is within tolerances. Transfer is then possible: - without a break in the supply of power. Because the voltages are in phase, the SCRs on the two channels of the static switch have zero voltage at the same time, - without disturbing the load. The load is transferred to a bypass line that is within tolerances. When standby power is not within tolerances, the inverter desynchronises and operates autonomously with its own frequency. Transfer is disabled. It can, however, by carried out manually. Note 1. This function greatly increases reliability due to the very small probability of a downstream overload and a standby-power failure occurring at the same time. Note 2. To ensure correct operation of the bypass line, discrimination must be ensured between the protection device upstream of the bypass AC input (on the MLVS outgoer) and those on the UPS outgoing circuits (see information on discrimination below). APC by Schneider Electric 05/2009 edition ch. 5 - p. 23 UPS components and operation (cont.) Maintenance mode (on maintenance bypass, see fig. 5.9 right-hand side) Maintenance is possible without interrupting load operation. The load is supplied with standby power via the maintenance bypass. Transfer to the maintenance bypass is carried out using manual switches. The rectifier/charger, inverter and static switch are shut down and isolated from power sources. The battery is isolated by its protection circuit breaker. Bypass mode (static bypass). Maintenance mode (maintenance bypass). Fig. 5.9. Bypass mode and maintenance mode. UPS configurations Parallel UPS with redundancy Chapter two is entirely devoted to a presentation of the various configurations. Below is some additional information on parallel connection for redundancy. It concerns MGETM GalaxyTM UPSs in particular. The modular SymmetraTM UPSs also use parallel connection. Configurations, see ch. 2. Types of parallel configurations There are two types of parallel configurations. Integrated parallel UPS units This upgradeable configuration can be started using a single UPS unit with an integrated static bypass and manual maintenance bypass. For configurations with more than two UPS units, a common maintenance bypass is housed in an external cubicle (see fig. 5.10). Parallel UPS units with a centralised static-switch cubicle (SSC) The static-switch cubicle comprises an automatic bypass and a maintenance bypass that are common for a number of UPS units without a bypass (see fig. 5.11). This configuration, less upgradeable than the previous due to the rating of the bypass, offers greater reliability (SSC and UPS units are independent). Modular UPSs UPSs of the SymmetraTM range are made up of dedicated and redundant modules (power, intelligence, battery and bypass). Modular design with plug-in power modules improves dependability, in particular maintainability and availability, as well the upgradeability of the installation. Redundancy Redundancy in parallel configurations can be N+1, N+2, etc. This means that N UPS units are required to supply the load, but N+1 or N+2 are installed and they all share the load. See the example below. APC by Schneider Electric 05/2009 edition ch. 5 - p. 24 UPS components and operation (cont.) Example Consider a critical load with a 100 kVA rating. 2+1 redundancy - 2 UPS units must be capable of fully supplying the load if redundancy is lost. - Each UPS unit must therefore have a 50 kVA rating. - 3 UPS units normally share the 100 kVA load, i.e. each supplies 33.3 kVA. - The 3 UPS units normally operate at a percent load of 33.3 / 50 = 66.6%. - Integrated parallel UPS units are each equipped with a static bypass. Transfer is managed such that the three UPS units transfer to the bypass simultaneously, if necessary. Fig. 5.10. Integrated parallel UPS units with common maintenance bypass and 2+1 redundancy. Operation with all units OK (redundancy available). Loss of redundancy - One UPS unit shuts down, the two remaining units operate at 100%. - The faulty UPS unit can be serviced due to the maintenance bypass. Fig. 5.11. Integrated parallel UPS units with common maintenance bypass and 2+1 redundancy. Operation following loss of redundancy. APC by Schneider Electric 05/2009 edition ch. 5 - p. 25 Electromagnetic compatibility (EMC) Electromagnetic disturbances Electromagnetic disturbances All electromagnetic disturbances involve three elements. A source A natural source (atmosphere, earth, sun, etc.) or, more often, an industrial source (electrical and electronic devices). The source generates disturbances through sudden (pulse) variations in electrical values (voltage or current), defined by: A wave form, A wave amplitude (peak value), A spectrum of frequencies, A level of energy. A coupling mode Coupling enables transmission of disturbances and may be: Capacitive (or galvanic), for example via transformer windings, Inductive, by a radiating magnetic field, Conducted, by a common impedance, via an earthing connection. A victim This is any device likely to be disturbed, and which malfunctions due to the presence of the disturbances. Examples Sources In low-voltage installations, sources include suddenly varying currents resulting from: Faults or short-circuits, Electronic switching, High-order harmonics, Lightning or transformer breakdown. Frequencies may be low (< 1 MHz) for power frequencies and their harmonics or high (> 1 MHz) for lightning. Coupling Capacitive: transmission of a lightning wave via a transformer. Inductive: radiation of a magnetic field created by one of the above currents. Radiation creates an induced electromotive force, that is an induced disturbing current, in the loops of conductors made up of the cables supplying devices and the earthing conductors of the devices. As in indication, a radiation of 0.7 A/m can disturb a video monitor. That corresponds to the field created 2.2 m around a conductor carrying a current of 10 A. Conducted (common impedance): increase in the potential of an earthing connection. EMC standards and recommendations Disturbances Emission, immunity, susceptibility An electric device is installed in an environment that may be more or less disturbed electromagnetically. It must be seen as both a source and possible victim of electromagnetic disturbances. Depending on the point of view, on may speak of: The emission level for a source, The compatibility level for an environment, The immunity and susceptibility levels for a victim. These notions are discussed on the next page in the section on disturbance levels defined by the standards. APC by Schneider Electric 05/2009 edition ch. 5 - p. 26 Electromagnetic compatibility (EMC) (cont.) Disturbance levels Standard IEC 6100-2-4 defines a number of disturbance levels for EMC: Level 0: no disturbance, Emission level: maximum level authorised for a user on a public utility or for a device, Compatibility level: maximum disturbance level expected in a given environment, Immunity level: level of disturbance that a device can withstand, Susceptibility level: level starting at which a device or system malfunctions. Consequently, for devices and equipment that are considered: Sources, limits (emission levels) must be set for disturbances emitted by devices to avoid reaching compatibility levels, Victims, they must also withstand disturbance levels higher than the compatibility levels, if they are exceeded, which is permissible on a transient basis. These higher levels are the immunity levels. EMC standards set these levels. List of EMC standards, see the section on page 34 on EMC standards. Fig. 5.12. EMC disturbance levels for disturbing/disturbed devices. Measured values Devices are subjected to tests. Five major values are measured: CE - conducted emissions, RE - radiated emissions, ESD - electrostatic discharges, CS - conducted susceptibility, RS - radiated susceptibility. The tests require major resources, namely a Faraday cage for conducted emissions and susceptibility and an anechoic chamber for radiated emissions. APC by Schneider Electric has a certified anechoic test chambers. Fig. 5.13. Five major measurement values. APC by Schneider Electric 05/2009 edition ch. 5 - p. 27 UPS standards Scope and observance of standards Scope of standards Standards cover the following aspects: UPS design, Safety of persons, Performance levels, Electrical environment (notably harmonic disturbances and EMC), Ecological environment. Standards on UPSs have become much more precise, notably with the creation of the European EN standards and their harmonisation with a part of the previously existing IEC standards. Observance of standards and certification Observance of standards guarantees the reliability and the quality of a UPS, its compatibility with the loads supplied as well as with the technical, human and natural environment. Statement by a manufacturer of conformity with standards is not, in itself, a sufficient indication of quality. Only certification by recognised organisations is a true guarantee of conformity. To that end, performance levels of UPSs from APC by Schneider Electric with respect to standards are certified by organisations such as TÜV and Veritas. CE marking CE marking was created by European legislation. It is mandatory for free circulation of goods in the EU. Its purpose is to guarantee, through respect of the corresponding European directives: That the product is not dangerous (Low-voltage Directive), That it does not pollute (Environment Directive) and its electromagnetic compatibility (EMC Directive). Before placing the CE marking on a product, the manufacturer must run or have run checks and tests which ensure conformity of the product with the requirements in the applicable directive(s). It is NOT a certification standard or mark of conformity. It does not signify that the product complies with national or international standards. It is not a certification as defined by French law (law dated 3 June 1994). What is more, the CE marking is placed on a product under the exclusive responsibility of the manufacturer or the importer. It does not imply inspection by a certified external organisation. Not all labels carry the same implications for manufacturers. Conformity with standards and specified levels of performance must be certifiable by an organisation. This is not the case for CE marking which authorises selfcertification. Main standards governing UPSs UPSs from APC by Schneider Electric comply (certified by TÜV and Veritas) with the main applicable international standards. Safety IEC 60950-1 / EN 60950-1 Information technology equipment - Safety - Part: General requirements IEC 62040-1/ EN 62040-1 Uninterruptible power systems (UPS) - General and safety requirements for UPS. IEC 62040-3 / EN 1000-3 Uninterruptible power systems (UPS) - Method of specifying the test and performance requirements. IEC 60439 Low-voltage switchgear and controlgear assemblies. LV directive: 2006/95/EC APC by Schneider Electric 05/2009 edition ch. 5 - p. 28 UPS standards (cont.) Electrical environment, harmonics and electromagnetic compatibility (EMC) Harmonics IEC 61000-2-2 / EN 61000-2-2 Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. (see Table 5-A on the next page) IEC 61000-3-2 / EN 61000-3-2 Limits for harmonic current emissions (equipment input current 16 A/ph). IEC 61000-3-4 / EN 61000-3-4 Limits for harmonic current emissions (equipment input current > 16 A/ph). IEC 61000-3-5 / EN 61000-3-5 Limitation of voltage fluctuations and flicker. EN 50160 Voltage characteristics of public networks. (see Table 5-B on the next page). IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems. EMC EN 50091-2 UPS - EMC. IEC 62040-2/ EN 62040-2 Uninterruptible power systems (UPS) - Electromagnetic compatibility (EMC) requirements. EMC Directive 2004/108/EC For equipment liable to cause or be affected by electromagnetic disturbances. Quality Design , production and servicing in compliance with standard ISO 9001 - quality organisation. Ecological environment Manufacturing in compliance with standard ISO 14001. APC by Schneider Electric 05/2009 edition ch. 5 - p. 29 UPS standards (cont.) Acoustic noise ISO 3746 Sound power levels. ISO 7779 / EN 27779 Measurement of airborne noise emitted by computer and business equipment. Tables on harmonic-compatibility levels Table 5-A. Compatibility levels for individual harmonic voltages in low voltage networks as indicated in standards IEC 61000-2-2 / EN 61000-2-2. Odd harmonics non multiple Odd harmonics multiple of 3 Even harmonics of 3 Harmonic Harmonic Harmonic Harmonic Harmonic Harmonic order n voltage as a % order n voltage as a % order n voltage as a % of fundamental of fundamental of fundamental 5 6 3 5 2 2 7 5 9 1.5 4 1 11 3.5 15 0.3 6 0.5 13 3 21 0.2 8 0.5 17 2 >21 0.2 10 0.5 19 1.5 12 0.5 23 1.5 >12 0.2 25 1.5 0.2 >25 0.2+0.5x25/n Resulting THDU < 8% (for all harmonics encountered among those indicated). Table 5-B. Compatibility levels for harmonic voltages according to the type of equipment as indicated in standard EN 50160. (1) Order of the voltage Class 1 Class 2 Class 3 harmonic generated (sensitive systems and (industrial and public (for connection of equipment) % of networks) % of major polluters) % of fundamental fundamental fundamental 2 2 2 3 3 3 5 6 4 1 1 1.5 5 3 6 8 6 0.5 0.5 1 7 3 5 7 8 0.5 0.5 1 9 1.5 1.5 2.5 10 0.5 0.5 1 11 3 3.5 5 12 0.2 0.2 1 13 3 3 4.5 TDHU 5% 8% 10% (1) Class 2 corresponds to the limits of Table A of standards IEC 61000-2-2 / EN 61000-2-2. APC by Schneider Electric 05/2009 edition ch. 5 - p. 30 Energy storage Possible technologies Energy storage in UPSs The energy-storage systems used by UPSs to backup the primary source must have the following characteristics: Immediate availability of electrical power, Sufficient power rating to supply the load, Sufficient backup time and/or compatibility with systems providing long backup times (e.g. an engine generator set or fuel cells). Evaluation of the available technologies See WP 65 The technical watch established by APC by Schneider Electric resulted in in-depth examination of the following technologies: Batteries, Supercapacitors (ultracapacitors), Flywheels, Superconducting magnetic energy storage (SMES). For more information, see WP 65 (White Paper 65: "Comparing Data Center Batteries, Flywheels, and Ultracapacitors". The battery solution is discussed below. Batteries The battery solution Batteries are by far the most commonly employed solution today for energy storage in UPSs. They are the dominant solution due to low cost, proven effectiveness and storage capacity, but nonetheless have a number of disadvantages in terms of size, maintenance and the environment. At the power ratings under consideration, they offer backup times in the ten-minute range, enough to ride through long outages and wait for start-up of an engine generator set for extended runtime. For its SymmetraTM PX range, APC by Schneider Electric also offers extended runtime solutions based on fuel cells, with the FCXR (Fuel Cell eXtended Run) product range. This solution significantly reduces the environmental impact and floorspace requirements with respect to solutions combining batteries and an engine generator set. Electrochemical energy storage using batteries, where applicable backed up by a thermal engine generator set, is the commonly used solution to protect critical loads using UPSs. Fig. 5.14. Energy storage using a battery and an engine generator set for long backup times. APC by Schneider Electric 05/2009 edition ch. 5 - p. 31 Energy storage (cont.) Types of industrial batteries Battery families A battery is a set of interconnected cells. Depending on the type of cell, there are two main families of batteries: Lead-acid batteries, Nickel cadmium batteries. Cells may also be of the : Recombination type sealed batteries The gas recombination rate is at least 95% and they therefore do not require water to be added during service life (hence the term "sealed"), Vented type vented batteries They are equipped with ports to: - release to the atmosphere the oxygen and hydrogen produced during the different chemical reactions, - top off the electrolyte by adding distilled or demineralised water. Batteries used in UPSs The main types of batteries used in conjunction with UPSs are: Sealed lead-acid batteries, used 95% of the time because they are easy to maintain and do not require a special room, these batteries can be installed in office environments and in any position, Vented lead-acid batteries, Vented nickel-cadmium batteries. Vented batteries impose greater constraints in terms of maintenance (checks on the electrolyte level) and their position (only in the vertical position). Lithium-polymer batteries are currently being studied for use in UPSs. For use in conjunction with its UPS ranges, APC by Schneider Electric recommends sealed lead-acid batteries, but nonetheless offers a wide selection of other types. It offers all three types of battery for all the available service lives. Capacity levels and backup times may be adapted to suit the user's needs. The proposed batteries are also perfectly suited to UPS applications in that they are the result of collaboration with leading battery manufacturers. Battery selection, see Ch. 1 p. 46. Installation modes Depending on the UPS range, the battery capacity and backup time, the battery is: Sealed type and housed in the UPS cabinet, Sealed type and housed in one to three cabinets, Vented or sealed type and rack-mounted. Cabinet mounting This installation method (see fig. 5.15) is suitable for sealed batteries. It is easy to implement and offers maximum safety. Batteries installed on racks On shelves (figure 5.16) This installation method is possible for sealed batteries or maintenance-free vented batteries which do not require topping up of their electrolyte. Tier mounting (figure 5.17) This installation method is suitable for all types of batteries and for vented batteries in particular, as level checking and filling are made easy. Fig. 5.15. Cabinet mounting. APC by Schneider Electric 05/2009 edition Fig. 5.16. Mounting on shelves. Fig. 5.17. Tier mounting. ch. 5 - p. 32 Energy storage (cont.) Constraints on batteries Atmospheric constraints The batteries supplied with UPSs from APC by Schneider Electric are designed to operate under the following conditions: Optimum temperature range: 15°C to 25°C, Optimum relative humidity range: 5% to 95%, Atmospheric pressure: 700 to 1060 hPa (0.7 to 1.06 bars). For other operating conditions, please consult us. Access Access must be provided for testing operations. Battery installed in UPS cabinet or other cabinet: comply with the clearances indicated in the "Dimensions and weights" in chapter 4. Battery installed on racks: select an installation method suited to the type of battery. Preliminary work: this aspect is important as it involves safety. It is discussed in Ch. 1 p. 49. Main battery parameters Backup time For a given battery, the backup time depends on: The power that must be supplied, a low value increases the available autonomy, The discharge conditions, a high discharge rate makes possible a lower shutdown voltage and thus increases the backup time, Temperature, within the recommended operating limits, the backup time increases with increasing temperature. Note, however, that a high temperature adversely affects battery service life, Ageing, battery backup time decreases with the age of the battery. APC by Schneider Electric offers a range of standard backup times (5, 6, 8, 10, 15 or 30 minutes and service lives (5 or 10 years or higher) and also caters to all specific requirements. Service life A battery is considered to reach the end of its service life when its real backup time has fallen to 50% of the specified backup time. The service life of a battery is basically enhanced by: Providing protection against deep discharge, Correct charger settings, in particular the ripple factor of the charge or float current, An optimum operating temperature, maintained between 15°C and 25°C. Recharge mode The charge cycle takes place in two steps: Step 1, a constant current limited to 0.1 C10 (one tenth of the battery capacity for a ten-hour discharge), Step 2, a constant voltage, at the maximum permissible value. The charge current regularly decreases and reaches the floating value. Fig. 5.18. Battery charge cycle. APC by Schneider Electric 05/2009 edition ch. 5 - p. 33 Energy storage (cont.) Battery management for MGETM GalaxyTM ranges DigibatTM TM TM To manage the above parameters, all MGE Galaxy UPSs from APC by TM Schneider Electric come as standard with the microprocessor-based Digibat TM battery-monitoring system (dedicated DSP for real-time processing). Digibat , an easy-to-use system, offers advanced and flexible functions as well as physical and computer-aided protection for the battery. It provides a high level of safety, true measurement of the backup time and optimises battery service life. For example, for an MGE Galaxy 5000 UPS, the functions include: Automatic entry of battery parameters, Measurement of the real backup time remaining, taking into account the age of the battery, the temperature and the load level, Estimate of remaining battery life (1), Battery test to preventively detect battery-function faults (1), Regulation of battery voltage with respect to the temperature to optimise battery life, Automatic battery-discharge test at adjustable time intervals. Protection includes: Protection against deep discharge (depending on the discharge rate) and battery isolation using a circuit breaker which automatically opens when the backup time, multiplied by two plus two hours, has elapsed, Limiting of the recharge current in the battery (0.05 C10 to 0.1 C10), Progressive audio alarm signalling the end of the backup time, Numerous automatic tests. (1) APC by Schneider Electric exclusive patents. Fig. 5.19. Digibat TM Temperature monitoring TM TM MGE Galaxy UPSs can also be equipped with the Temperature Monitoring module used to: Optimise the charger voltage depending on the temperature in the battery room, Warn the user if preset permissible temperature limits are exceeded, Refine the estimate on battery backup time carried out by the standard system $. Natural ventilation of battery cabinets avoids battery temperature rise. Environment Sensor is also a simple means to monitor temperature and humidity. It can be used to launch shutdown when combined with software running the module. Battery monitoring APC by Schneider Electric also offers the B2000 and Cellwatch autonomous and communicating battery-monitoring systems which immediately detect and locate all battery faults. These systems monitor each battery block or cell and make possible predictive maintenance. APC by Schneider Electric 05/2009 edition ch. 5 - p. 34 UPS / generator-set combination Use of a generator Long backup times An engine generator set is made up of an internal-combustion engine driving a generator that supplies the distribution system. The backup time of an engine generator set depends on the quantity of fuel available. In some installations, the required backup time in the event of a utility outage is such that it is preferable to use an engine generator set to back up utility power (figure 5.20). This solution avoids using large batteries with very long backup times. Though there is no general rule in the matter, a generator is often used for backup times exceeding 30 minutes. Critical installations requiring very high availability levels and with high down-time costs (e.g. data centres) systematically combine UPSs and engine generator sets. The battery backup time of the UPS must be sufficient for generator start-up and connection to the electrical installation. Connection is generally carried out on the main LV switchboard using an automatic source-changeover system. The time required for changeover depends on the specific characteristics of each installation, notably the start-up sequence, load shedding, etc. Fig. 5.20. UPS / generator-set combination. UPS / generator-set combination UPS / generator-set compatibility A number of factors must be taken into account when using an engine generator set to provide long backup-time power to UPSs. Load step changes In the event of emergency conditions requiring connection of the installation to the generator set, heavy loads can result in high inrush currents which can cause serious generator-set operating problems. To avoid such phenomena, UPSs from APC by Schneider Electric are equipped with a system ensuring gradual start-up of the charger. The walk-in lasts approximately ten seconds. What is more, when utility power returns, the charger may be stopped gradually via an auxiliary switch in order to avoid disturbing the other loads. APC by Schneider Electric 05/2009 edition ch. 5 - p. 35 UPS / generator-set combination (cont.) Fig. 5.21. Gradual start of the UPS rectifier during operation on generator power. Capacitive currents The generator can supply only relatively low capacitive currents (10 to 30 % of In). When an LC filter is installed, the main difficulty lies in the gradual start-up of the rectifier on generator power, when active power is equal to zero and the generator supplies only the capacitive current for the filter. Consequently, the use of LC filters must be correctly analysed to ensure that operation complies with manufacturer specifications. Use of compensated LC filters with a contactor solves this problem. For UPSs with a PFC rectifier, compatibility is total. LC filters and generators, see Ch. 1 p. 26. Respective UPS and generator power ratings A UPS equipped with a PFC rectifier has a high input power factor (greater than 0.9). The engine generator set can therefore be used to maximum effectiveness. For LC filters, compensated filters with a contactor solve the problem concerning capacitive currents. Compatibility of power ratings between modern UPSs and engine generator sets avoids all problems of derating. Stability of generator frequency During operation on engine generator set power, fluctuation in the generator frequency may occur due to variations in the speed of the thermal motor for which the regulation functions are not instantaneous. These variations are due to changes in the load. Examples are start-up of the engine generator set itself (until it reaches its rated speed), start-up of other loads supplied by the engine generator set (elevators, air-conditioning systems), or shedding of loads. This may create problems with line-interactive UPSs whose output frequency is identical to that of the input. Generator frequency variations may lead to multiple transfers to battery power (frequency outside tolerances) and returns to utility power (when the inverter has stabilised the frequency, but the generator itself has not yet stabilised), resulting in "hunting" phenomena (instability around the frequency setpoint). With double-conversion UPSs, the regulation of the output power by the inverter avoids this problem. Double-conversion UPSs are totally compatible with the frequency fluctuations of engine generator sets. This is not the case for line-interactive UPSs. Harmonics The subtransient reactance X"d of a generator is generally higher than the shortcircuit voltage Uscx of a transformer (two to four times higher). Any harmonic currents drawn by the UPS rectifier may have greater impact on the voltage harmonic distortion on the upstream busbars. With PFC rectifier technology, the absence of upstream harmonics avoids this problem. APC by Schneider Electric 05/2009 edition ch. 5 - p. 36 UPS / generator-set combination (cont.) Review of inrush currents On start-up, a number of loads cause major inrush currents (switching surges, startup peaks), which last a certain time. For the UPS, these currents represent an apparent load Sa (kVA) that is greater than Sn (kVA), which can be supplied under steady-state conditions. The value of Sa to be taken into account in sizing UPS power is calculated on the basis of these inrush currents. Below are indications on these currents caused by common load devices. Motors Motors are generally of the three-phase asynchronous type (95% of all motors). The additional power requirement corresponds to the start-up current defined by (fig. 5.22): Id (5 to 8 In, rated rms value) for a time td (1 to 10 seconds), Imax = 8 to 12 In, for 20 to 30 milliseconds. The power drawn that must be taken into account (neglecting the peak effect of Imax) is: Sa (kVA) = Un Id 3 during td. LV/LV transformers Transformer switching produces current peaks with amplitudes that are damped according to an exponential decay with a time constant (see fig. 5.23). i = I1st peak exp -t/ where is a few cycles (30 to 300 ms). I1st peak = k In (where k is given, generally 10 to 20). Indications generally include the number of cycles the phenomenon lasts and the value of the various peaks as a percentage of I1st peak. The corresponding inrush current is generally calculated on the basis of (see example): Sa (kVA) = Un I1st peak 3 , i.e. Sa (kVA) = k Un In 3 during the number of cycles. Example of an inrush current damped in four cycles with: st 1 peak (100%): k In (k from 10 to 20), nd 2 peak 30 %: 0.3 k In, rd 3 peak 15 %: 0.15 k In. The total of the rms values of the currents corresponding to the various peaks (Ipeak (1) / 2 ) is: k In (1 0,3 0,15 ) K In 1,45 k In 2 2 This is roughly equivalent to the value of the first peak alone. (1) Considering the current peaks as sine waves; note that some manufacturers indicate an rms value of Ipeak / 2. Computer loads Switch-mode power supplies are non-linear loads. The current for a single-phase load has a wave form similar to that shown in figure 5.27. There can be a peak during the first half wave of approximately 2 In. However, it is generally much lower than this and can be neglected. Fig. 5.22. Curve for direct on- Fig. 5.23. LV/LV transformer line starting of a three-phase switching current. asynchronous motor. APC by Schneider Electric 05/2009 edition Fig. 5.24. Computer load starting current. ch. 5 - p. 37 Harmonics Harmonics Origin of harmonics The increasing use of computing, telecommunications and power-electronics devices have multiplied the number of non-linear loads connected to power systems. These applications require switch-mode power supplies which transform the voltage sine wave into periodic signals of different wave forms. All these periodic signals of frequency f are the product of superimposed sinusoidal signals with frequencies that are multiples of f, known as harmonics (see the section "Characteristic harmonic values" dealing with the Fourier theorem below, on page 40). Figure 5.25 illustrates this showing the initial current (the fundamental) and the third-order harmonic. This figure shows what happens when a thirdorder harmonic (150/180 Hz) is superimposed on the fundamental frequency (50/60 Hz). The frequency of the resulting periodic signal is that of the fundamental, but the waveform is distorted. Fig. 5.25. Example of harmonics. The increased presence of harmonics is a phenomenon that concerns all electrical installations, commercial and industrial, as well as residential. No modern electrical environment is exempt from these disturbances caused by devices such as PCs, servers, fluorescent tubes, air-conditioners, variable-speed drives, discharge lamps, rectifiers, static power supplies, microwave ovens, televisions, halogen lamps, etc. All these loads are termed "non-linear". Consequences of harmonics Harmonics disturb, increasingly severely, all sorts of activities, ranging from factories producing electronic components and data-processing systems to pumping stations, telecommunications systems, television studios, etc., because they represent a significant part of the current drawn. There are three types of negative consequences for users: Impact on the electrical installation Harmonics increase the value of the rms current with respect to that of the rated sinusoidal current. The result is temperature rise (sometimes significant) in lines, transformers, generators, capacitors, cables, etc. The hidden costs of accelerated aging in such devices can be very high. Impact on applications Harmonic currents circulate in the source and line impedances, thus generating voltage harmonics which lead to voltage distortion on the busbars upstream of the non-linear loads (figure 5.26). The distortion of the supply voltage (upstream THDU - Total harmonic distortion in voltage) may disturb the operation of certain sensitive devices connected to the these busbars. What is more, for TNC systems where N and PE conductors are combined to form a PEN conductor, the zero-sequence third-order harmonics cumulate in the neutral conductor. This unbalance current in the neutral can disturb circuits interconnecting low-current devices and may require oversizing of the neutral. APC by Schneider Electric 05/2009 edition ch. 5 - p. 38 Harmonics (cont.) Fig. 5.26. Voltage distortion due to reinjection of harmonic currents by non-linear loads. Impact on the available electrical power Harmonics represent an outright loss of current (up to 30% more current consumed). The user must pay more for less available power. Precautions General There are a number of traditional solutions to limit harmonics: installation of tuned passive filters, installation in parallel of several cables with medium-sized cross sections, separation of non-linear loads and sensitive loads behind isolating transformers. However, these solutions have two major disadvantages: limitation of harmonics is effective only in the existing installation (the addition or removal of loads can render it ineffective), implementation is difficult in existing installations. SineWave active harmonic conditioners (see chapter 3) avoid these disadvantages. Much more effective than other solutions, they may be used with all types of loads and can selectively eliminate harmonics ranging from the 2nd to the 25th order. Elimination of harmonics, see Ch. 3. UPSs Due to the rectifier/charger, a UPS is a non-linear load for its power source. UPSs from APC by Schneider Electric offer perfect control over upstream harmonics by using "clean" PFC rectifiers or filters (MGE Galaxy PW and 9000). Upstream of the UPS, the total voltage distortion remains within limits that are acceptable for the other devices connected to the same busbars. APC by Schneider Electric 05/2009 edition ch. 5 - p. 39 Harmonics filters (cont.) Characteristic harmonic values Current values Harmonic expansion of a periodic current The Fourier theorem indicates that any periodic function with a frequency f may be represented as the sum of terms (series) composed of: a sinusoidal term with frequency f, called the fundamental frequency, sinusoidal terms with frequencies that are whole multiples of the fundamental frequency, i.e. the harmonics, a DC component, where applicable. Application of the Fourier theorem to the currents of non-linear loads indicates that a periodic current I(t), of whatever form at frequency f (50 or 60 Hz), is the sum of harmonic sinusoidal currents defined by: I( t) IH1 2 sin(t 1) IHn 2 sin(nt n) n 2 where IH1 is the rms value of the fundamental current at frequency f (50 or 60 Hz), = 2 f is the angular frequency of the fundamental, 1 is the phase displacement between the fundamental current and the voltage, IHn is the rms value of the nth harmonic, at frequency nf, n is the phase displacement between the nth harmonic current and the voltage. It is important to evaluate the harmonics (n 2) with regards to the fundamental (n = 1) to determine to what degree the function differs from the fundamental. To that end, the values below are taken into account. Current individual harmonic content This value expresses the ratio in percent between of the rms value of the given harmonic and that of the fundamental. IHn Ihn % 100 IH1 All the harmonics present in a given current with the indication of their relative importance (Ihn values) constitute the harmonic spectrum of the current. Generally speaking, the influence of the orders above the 25th is negligible. Current total harmonic distortion This distortion is called THDI (Total Harmonic Distortion where I is for the current). It expresses the ratio between the rms value of all harmonics (n 2) and that of the fundamental. The THDI is also expressed in terms of the individual harmonics. IH n n 2 THDI% 100 IH1 2 100 IHn IH n 2 2 1 Ih % 2 n n 2 Note. Harmonic contents are sometimes expressed with respect to the complete signal Irms, and not the fundamental (IEC documents). Here, we use the definition of the CIGREE, which uses the fundamental. For the low harmonic contents analysed in the following pages, the two definitions produce virtually identical results. Rms value of a current with harmonics The rms value of an alternating current with a period T is: Irms 1 T T 0 I t dt 2 After calculation and using harmonic representation, this can be expressed as: Irms IH n 2 n 1 where IHn = rms value of the nth harmonic. APC by Schneider Electric 05/2009 edition ch. 5 - p. 40 Harmonics filters (cont.) The rms value is also expressed as: IH Irms IH12 n 2 or: n 2 Ieff IH1 1 n2 IHn IH1 2 hence: Irms IH1 1 Ih n 2 IH1 1 THDI2 n 2 Ihn = Ihn% / 100 (individual level expressed as a value and not as a percentage). THDI = THDI% / 100 (distortion expressed as a value and not as a percentage). The rms value of the current is that of the fundamental, multiplied by a coefficient which is due to the harmonics and is a function of the distortion. One effect of harmonics is therefore to increase the rms value of the current, which can lead to temperature rise and therefore require oversizing of conductors. The lower the distortion, the less need for oversizing. Example Input current of a three-phase rectifier. Harmonic distortion levels Ih5 = 33% Ih7 = 2.7% Ih11 = 7.3% Ih13 = 1.6% Ih17 = 2.6% Ih19 = 1.1% Ih23 = 1.5% Ih25 = 1.3% THDI = 35% Fig 5.27. Example of the spectrum of a harmonic current. THDI% Ih % 2 n n 2 The value under the square root sign is: 332 + 2.72 + 7.32 + 1.62 +2.62 + 1.12 + 1.52 +1.32 = 1164 consequently THDI% 34% and THDI = 0.34. Ieff IH1 1 THDI2 = IH1 1 0.34 2 = 1.056 x I1 The rms value of this current is therefore 5.6% higher than the rms value of the fundamental, i.e. than the rated current containing no harmonics, with a corresponding temperature rise. Voltage values At the terminals of a non-linear load, through which a distorted periodic AC current flows, the voltage is also periodic with a frequency f and it is also distorted with respect to the theoretical sinusoidal wave. The relation between voltage and current is no longer governed by Ohm's linear law, because it is applicable only for sinusoidal voltage and current. It is possible, however, to use a Fourier expansion for the voltage and to define, similar to the current and with the same results, the following values: Voltage individual harmonic content UHn Uhn % 100 UH1 The harmonic spectrum can also be calculated for the voltage. APC by Schneider Electric 05/2009 edition ch. 5 - p. 41 Harmonics filters (cont.) Voltage total harmonic distortion UH n 2 n 2 THDU% 100 100 UH1 UHn UH1 n 2 2 Uh 2 n n 2 THDU for Total Harmonic Distortion, where U is for the voltage. Rms value of a voltage with harmonics Irms IH n 2 n 1 Which, similar to the current, can also be expressed as: Urms UH1 1 Uh n 2 IH1 1 THDU2 n2 The rms value of the voltage is that of the fundamental, multiplied by a coefficient which is due to the harmonics. Power values Power factor in the presence of harmonics On the basis of the active power at the terminals of a non-linear load P (kW) and the apparent power supplied S (kVA), the power factor is defined by: P (kW ) S (kVA ) This power factor does not express the phase displacement between the voltage and the current because they are not sinusoidal. However, it is possible to define the displacement between the voltage fundamental and the current fundamental (both sinusoidal), by: P1(KW ) cos 1 S1(kVA ) where P1 and S1 are the active and reactive power, respectively, corresponding to the fundamentals. Standard IEC 146-1 defines the distortion factor: cos 1 When there are no harmonics, this factor is equal to 1 and the power factor is simply the cos . Power in the presence of harmonics Across the terminals of a balanced, three-phase linear load, supplied with a phase-to-phase voltage u(t) and a current I(t), where the displacement between u and i is , the apparent power in kVA, depending on the rms values U and I, is: S UI 3 The active power in kW is: P = S cos The reactive power in kvar is: Q = S sin Where: S P 2 Q2 At the terminals of a non-linear load, the mathematical definition of P is much more complex because U and I contain harmonics. It can however be expressed simply as: .P = S . ( = power factor) If U1 and I1 are the fundamentals displaced by 1, it is possible to calculate the corresponding apparent, active and reactive power by: S1 U1 I1 3 P1 = S1 cos 1 and Q1 = S1 sin 1. The total apparent power is: S P12 Q12 D2 where D is the distortion power, due to the harmonics. APC by Schneider Electric 05/2009 edition ch. 5 - p. 42 Non-linear loads and PWM technology Non-linear load performance of UPSs using PWM technology Importance of the UPS output impedance Equivalent diagram of an inverter output With respect to the load, an inverter is a perfect source of sinusoidal voltage V0 in series with an output impedance Zs. Figure 5.28 shows the equivalent diagram of the inverter output when a load is present. The inverter output is a perfect voltage source Vc = impedance across the load terminals. V0 in series with an output impedance Zs. Vs = impedance at the inverter output. ZL = line impedance. Zc = load impedance. Fig. 5.28. Equivalent diagram of an inverter output. Effects of different load types For a linear load, the impedances Zs, ZL, Zc are considered at the angular frequency = 2 f corresponding to the distribution frequency (f = 50 or 60 Hz), giving V0 = (Zs + ZL + Zc) I For a non-linear load, the harmonic currents drawn by the load flow through the impedances. For the fundamental and each individual harmonic, the rms values of the current and the voltage are related similarly and can be expressed as: - for the fundamental: U1 = (Zs + ZL + Zc) I1 - for each harmonic order k: UK = [Zs(kf) + ZL(kf) + Zc(kf)] IK The impedance values are considered at the frequency kf of the given order. Voltage distortion decreases with the individual levels of the voltage harmonics UK / U1. These levels are related to those of the harmonic currents IK/ I1 by the equation: [Zs(kf) + ZL(kf) + Zc(kf)] / (Zs + ZL + Zc). Consequently, for a given load current spectrum, the individual voltage harmonic levels and the total distortion (THDU) decrease with the impedance of the source and the cables at the given frequencies. Consequences of non-linear loads To reduce the effects of the harmonic currents (THDU at B and C), it is necessary, to the greatest extent possible, to: reduce the line impedance, ensure a low source impedance at the various harmonic frequencies. Good behaviour on the part of a UPS supplying non-linear loads requires a low output impedance at the various harmonic frequencies. Below is a presentation of the advantages of the PWM (pulse width modulation) chopping technique in this respect. APC by Schneider Electric 05/2009 edition ch. 5 - p. 43 Non-linear loads and PWM technology (cont.) UPS operating principle Chopping of the DC voltage by the inverter with filtering An inverter is made up of a converter that transforms the DC power supplied by the rectifier/charger or the battery into AC power. For example, on a single-phase UPS, there are two ways to convert the DC power, using either a half bridge (see fig. 5.29) or a full bridge (see fig. 5.30). The square-wave voltage obtained between A and B is then filtered to produce a sinusoidal voltage with a low level of distortion at the output. The switches represented here to illustrate the principle are controlled IGBTs. Fig. 5.29. Half-bridge DC/AC converter. Fig. 5.30. Full-bridge DC/AC converter. Practically speaking, the switches shown in figures 5.29 and 5.30 are IGBTs for which it is possible to control the relative on and off times. By controlling the on and off times, it is possible to "distribute" the voltage over the reference sinusoidal wave. This principle is known as PWM (pulse width modulation). It is shown in a simplified manner, with five square-wave pulses, in figure 5.31. The area of the voltage sinusoidal wave is equal to that of the square-wave pulses used to generate it. These areas represent the power supplied by the inverter to the load T over a given time, i.e. VIdt 0 The higher the chopping frequency (the higher the number of square-wave pulses), the better the regulation with respect to the reference wave. Chopping also reduces the size of the internal filter required on the LC output (see fig. 5.32). Fig. 5.31. DC/AC converter output voltage with five square-wave pulses per half-wave. APC by Schneider Electric 05/2009 edition Fig. 5.32. Inverter output filter. ch. 5 - p. 44 Non-linear loads and PWM technology (cont.) PWM inverters PWM chopping The PWM (pulse width modulation) chopping technique combines high-frequency chopping (a few kHz) of the DC voltage by the inverter and regulation of the pulse width for the inverter output, to comply with a reference sinusoidal wave. This technique uses IGBTs (insulated gate bipolar transistors) offering the advantages of voltage control and very short commutation times. Due to the high frequency, the regulation system can react quickly (e.g. 333 nanoseconds for a frequency of 3 kHz) to modify the pulse widths within a given period. Comparison with the reference voltage wave makes it possible to maintain the inverter output voltage within strict distortion tolerances, even for highly distorted currents. Functional diagram of a PWM inverter Figure 5.33 shows the functional diagram of a PWM inverter. The output voltage is continuously compared to the reference voltage Vref which is a sinusoidal wave with a very low level of distortion (< 1%). The difference in the voltage is processed by a corrector, according to a transfer function C(p), intended to ensure the performance and stability of control. The voltage from the corrector is then amplified by the DC/AC converter and its control system with a gain A. The Vm voltage supplied by the converter is filtered by the LC filter to supply the output voltage Vs. Practically speaking, it is necessary to take into account the impedance of the output transformer when it exists, to obtain the total inductance L. Often, the inductance is built into the transformer, which is why it is not included in diagrams. Fig. 5.33. Functional diagram of a PWM inverter. Output impedance of a PWM inverter It is possible to represent the above DC/AC converter and filter as a series impedance Z1 and a parallel impedance Z2 (see the left-hand side of fig. 5.34). The diagram can be modified to display the output impedance Zs. The equivalent diagram (right-hand side of fig. 42) shows: Z2 V'm = voltage measured under no-load conditions, i.e. V'm = Vm Z1 Z 2 Zs = impedance measured at the output with V'm short-circuited, i.e.: Zs = Z1 Z 2 Z1 Z 2 Fig. 5.34. Equivalent diagram of an inverter as seen from the output. APC by Schneider Electric 05/2009 edition ch. 5 - p. 45 Non-linear loads and PWM technology (cont.) Z2 is the transfer function of the filter, noted H(p). Z1 Z 2 To simplify, C(p) x A is replaced by (p) which represents the transfer function of the correction and amplification. It is thus possible to replace fig. 5.41 by the functional diagram in fig. 5.43. The ratio Fig. 5.35. Transformed functional diagram of a PWM-chopping inverter equipped with an output-voltage regulation system with modulated chopping frequency. It is possible to show that the inverter output impedance Zs in this case is equal to: Z1 Z' s (p) (for further information, consult Schneider Electric Cahier Technique document no. 159). This means that in the regulation pass band, the inverter output impedance is equal to the filter series impedance divided by the correction and amplification gain. Given the high gain in the regulation pass band, the output impedance is significantly reduced compared to impedance Z1 of an inverter without this type of regulation. Outside the regulation pass band, the inverter output impedance is equal to that of the filter, but remains low because it corresponds to the impedance of a highfrequency capacitor. Consequently, the output impedance is a function of the frequency (see fig. 5.36). The free-frequency PWM (pulse width modulation) technique considerably limits the output impedance. Comparison of different sources Output impedance of various sources The curves in figure 5.36 show the output impedances for various sources with equal output ratings as a function of the AC frequency. The impedances are plotted as a percent of the load impedance Zc. Transformers and generators - the curve is a straight line corresponding to the effect of the inductance L (the term which rapidly becomes dominant in the reactance with respect to the resistance and which increases linearly as a function of the frequency). Modern inverters implementing the PWM chopping technique with modulated chopping frequency - at all harmonic frequencies, the Zs/Zc ratio is: - less than that noted for other sources, - low and virtually constant. Conclusion The PWM inverter is the source offering by far the lowest output impedance in the presence of harmonics. It is clearly the best source on the market in terms of its aptitude to minimise the voltage distortion caused by non-linear loads. It is five to six times better than a transformer with an identical power rating. The new generation of UPSs implementing IGBTs and the PWM chopping technique with frequency modulation are the best sources of sinusoidal voltage, whatever the type of current drawn by the load. APC by Schneider Electric 05/2009 edition ch. 5 - p. 46 Non-linear loads and PWM technology (cont.) Fig. 5.36. Output impedance of different sources depending on the frequency. Free-frequency chopping Free-frequency chopping Free frequency is an improvement to the PWM technique. PWM chopping can use either of two techniques (fig. 5.37). Fixed-frequency chopping The chopping fronts occur at fixed, regular intervals corresponding to the chopping frequency over one period. The width of the pulses (square-wave pulses) can be modulated to conform to the reference within the fixed time interval. The two sine waves shown in the diagram correspond to the tolerance (< 1%) around the reference sine wave. Free-frequency chopping The chopping fronts do not necessarily occur at fixed intervals. Chopping adapts to the requirements of the regulation, i.e. the rate of change of the reference. The width of the commutation fronts decreases (the chopping frequency increases) as the rate of change of the reference sine wave increases. Conversely, the width of the commutation fronts increases (the chopping frequency decreases) as the rate of change of the reference decreases. On the whole, the average chopping frequency is the same as that for the fixed-frequency technique (approximately 3 kHz). But regulation is better because the commutation accelerates in the zones where the rate of change is high (see fig. 5.38). It can reach eight commutations per millisecond, i.e. a regulation time as low as 125 nanoseconds (compared to 300 ns for the fixed-frequency technique). The free-frequency technique increases the precision of the voltage regulation in PWM inverters compared to the fixed-frequency technique. APC by Schneider Electric 05/2009 edition ch. 5 - p. 47 Non-linear loads and PWM technology (cont.) The chopping frequency is fixed. Modulation takes place within fixed intervals, whatever the rate of change of the reference sine wave. Fixed frequency. The free chopping frequency increases where the rate of change of the reference is high. Modulation therefore takes place within intervals that are shorter when the rate of change of the reference sine wave increases. Free frequency. Fig. 5.37. PWM chopping with fixed-frequency and free-frequency regulation. Free-frequency switching Quality band with variations < 1% Output voltage curve Up to 8 commutations per millisecond Fig. 5.38. Regulation employing free-frequency commutation. APC by Schneider Electric 05/2009 edition ch. 5 - p. 48 PFC Rectifiers Standard and PFC rectifiers UPS units draw power from the AC distribution system via a rectifier/charger. With respect to the upstream system, the rectifier is a non-linear load drawing harmonics. In terms of harmonics, there are two types of rectifiers. Standard rectifiers These are three-phase rectifiers incorporating SCRs and using a six-phase bridge with standard chopping of the current. This type of bridge draws harmonic currents with orders of n = 6 k 1 (where k is a whole number), mainly H5 and H7, and to a lesser degree H11 and H13. Harmonics are controlled by using a filter. "Clean" PFC (Power Factor Correction) rectifier This type of rectifier comprises built-in IGBTs and a regulation system that adjusts the input voltage and current to a reference sine wave. This technique ensures an input voltage and current that are: perfectly sinusoidal, i.e. free of harmonics, in phase, i.e. an input power factor close to 1. With this type of rectifier, no filters are required. PFC rectifiers Operating principle The principle behind PFC rectifiers consists in forcing the current drawn to remain sinusoidal. To that end, they use the PWM technique presented above. The principle is that of a "voltage source" converter (see fig. 5.39), whereas the SineWave active harmonic conditioner uses a "current source" converter. The converter acts as a back-electromotive force (a "sinusoidal voltage generator") on the distribution system and the sinusoidal current is obtained by inserting an inductor between the utility power and the voltage source. Even if other non-linear loads increase the voltage distortion on the distribution system, the regulation can adapt to draw a sinusoidal current. The frequency of low residual harmonic currents is the frequency of the modulation and of its multiples. Frequency depends on the possibilities of the semiconductors used. Fig. 5.39. Operating principle of a clean "voltage generator" converter. Implementation Single-phase rectifier Figure 5.40 shows the operation of a single-phase rectifier. Voltage modulation is obtained by a controller that forces the current to follow a sinusoidal current reference. Transistor T and diode D make up the voltage modulator. The voltage u thus changes between 0 and Vs according to whether transistor T is in the on or off state. When transistor T conducts, the current in inductor L can only increase as the voltage is positive and u = 0. Therefore: di e >0 dt L PC by Schneider Electric 05/2009 edition ch. 5 - p. 49 PFC Rectifiers (cont.) When transistor T is off, the current in L decreases, provided that Vs is greater than V, so that: di e Vs >0 dt L For this condition to be fulfilled, voltage Vs must be greater than the peak voltage of V, i.e. the rms value of the AC voltage multiplied by 2 If this condition is fulfilled, the current in L can be increased or decreased at any time. The variation of the current in L with time can be forced by monitoring the respective on and off times of transistor T. Figure 5.41 shows the evolution of current IL with respect to a reference value. From the source viewpoint, the converter must act like a resistance, i.e. current i must be sinusoidal and in phase with e (cos = 1). By controlling transistor T, the controller forces IL to follow a sinusoidal current reference with full-wave rectification. The shape of I is thus necessarily sinusoidal and in phase with e. What is more, to keep voltage Vs at its nominal value at the output, the controller adjusts the mean value of IL. Fig. 5.40. Diagram of a clean, single-phase rectifier drawing a sinusoidal signal. Fig. 5.41. Evolution of current IL with respect to the reference. PC by Schneider Electric 05/2009 edition ch. 5 - p. 50 PFC Rectifiers (cont.) Three-phase rectifier/charger The basic circuit arrangement is shown in fig. 5.42. It is similar to that in fig. 5.40, with the inductor placed upstream of the rectifiers; the operating principle is also the same. The monitoring system controls each power leg and forces the current drawn on each phase to follow the sinusoidal reference. Fig. 5.42. Diagram of a clean, three-phase rectifier drawing a sinusoidal signal. PC by Schneider Electric 05/2009 edition ch. 5 - p. 51 PFC Rectifiers (cont.) PC by Schneider Electric 05/2009 edition ch. 5 - p. 52 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy Part 1 GENERAL 1.1. SUMMARY A. This specification describes a three-phase, on-line, continuous operation, solid-state uninterruptible power supply (UPS) with the option to run in parallel with identical units. The UPS shall operate as an active power control system, working in conjunction with the building electrical system to provide power conditioning and on-line power protection for the critical loads. 1.2. DESCRIPTION A. The UPS shall consist of the following easy to repair rectifier/inverter sections and easy to install internal and external battery units. B. The UPS shall be provided with separate feeds for rectifier/inverter section and the static bypass switch. C. Modes of operation: The UPS shall operate as an on-line system in the following modes: 1. Normal: The inverter and the rectifier shall operate in an on-line manner to continuously regulate the power to the critical load. The rectifier shall derive power from the AC input source and supply DC power to float charge the battery. 2. Battery: Upon failure of the AC input source, the critical load shall continue being supplied by the main inverter without any switching. The inverter shall obtain its power from the battery. There shall be no interruption in power to the critical load upon failure or restoration of the AC input source. 3. Recharge: Upon restoration of the AC input source, the UPS shall simultaneously recharge the battery and regulate the power to the critical load. 4. Static Bypass: The static bypass switch shall be used for transferring the critical load to input supply without interruption. Automatic re-transfer to normal operation shall also be accomplished with no interruption in power to the critical load. The static bypass switch shall be fully rated and shall be capable of manual operation. The UPS shall be able to recharge the batteries while supplying full power to the load via the static bypass switch. 5. Internal maintenance bypass switch: The UPS shall be provided with an internal manual bypass switch for supplying the load directly from the mains supply, while the UPS is taken out for maintenance. The switch should be removable when the individual UPS unit has to run in parallel with other units. 6. External Maintenance Bypass Panel (MBP): The external Maintenance Bypass Panel shall be used for paralleling of multiple UPS units (optional for single UPS unit) to supply the load directly from the mains supply, if the UPS system has to undergo maintenance or service. An UPS input, output, common output and bypass breaker shall be housed in the same lowvoltage assembly. The manual bypass breaker must be monitored by each UPS via an auxiliary contact. The Maintenance Bypass Panel must be housed in a wall mounted lowvoltage assembly that complements the appearance of the UPS. D. The UPS shall be provided with RS-232 signalling and WEB/SNMP integration. This system must provide a means for logging and alarming of all monitored points plus email notification. E. The UPS shall have nominal voltage of 3×400 (adjustable for 3×380, 3×415), 50Hz, L1, L2, L3, N, PE. F. The UPS will be capable of paralleling up to max 4 like kVA and type UPS systems for capacity. APC by Schneider Electric 05/2009 edition ch. 6 – spec1 – p. 1 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy G. The UPS shall be compatible with all types of data centres, data rooms and facilities. Dedicated service to one specific environment shall not be acceptable. 1.3. STANDARDS A. Safety: 1. 2. 3. 4. 5. B. IEC 60950-1 / EN 60950-1 Information technology equipment - Safety - Part: General requirements IEC 62040-1/ EN 62040-1 Uninterruptible power systems (UPS) - General and safety requirements for UPS. IEC 62040-3 / EN 1000-3 Uninterruptible power systems (UPS) - Method of specifying the test and performance requirements. IEC 60439 Low-voltage switchgear and controlgear assemblies. LV directive: 2006/95/EC Harmonics: 1. 2. 3. 4. 5. 6. C. IEC 61000-2-2 / EN 61000-2-2 Compatibility levels for low-frequency conducted disturbances and signalling in public lowvoltage power supply systems. IEC 61000-3-2 / EN 61000-3-2 Limits for harmonic current emissions (equipment input current ≤ 16 A/ph). IEC 61000-3-4 / EN 61000-3-4 Limits for harmonic current emissions (equipment input current > 16 A/ph). IEC 61000-3-5 / EN 61000-3-5 Limitation of voltage fluctuations and flicker. EN 50160 Voltage characteristics of public networks. IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems. EMC: 1. 2. 3. D. EN 50091-2 UPS - EMC. IEC 62040-2/ EN 62040-2 Uninterruptible power systems (UPS) - Electromagnetic compatibility (EMC) requirements. EMC Directive 2004/108/EC For equipment liable to cause or be affected by electromagnetic disturbances. Quality: 1. E. Design , production and servicing in compliance with standard ISO 9001 - quality organisation. Ecological environment: 1. F. Manufacturing in compliance with standard ISO 14001. Acoustic noise 1. 2. APC by Schneider Electric ISO 3746 Sound power levels. ISO 7779 / EN 27779 Measurement of airborne noise emitted by computer and business equipment. 05/2009 edition ch. 6 – spec1 – p. 2 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy 1.4. CLASSIFICATION A. Classification according to EN/IEC 62040-3: VFI-SS-112 1.5. SUBMITTALS A. Proposal Submittals 1. 2. 3. 4. 5. 6. 7. 8. 9. Bid system bill of materials. Product catalogue sheets or equipment brochures. Product guide specifications. System single-line operation diagram. Floor layout. Capacity data Piping connection drawing. Installation guide. Drawings for requested optional accessories. B. Delivery Submittals 1. 2. 3. Installation manual, which includes instructions for storage, handling, examination, preparation, installation, and start-up of all systems. User manual, which includes operating instructions. As built equipment drawings. 1.6. QUALIFICATIONS A. Manufacturer experience: The manufacturer shall have a minimum of 20 years experience in the design, manufacture, and testing of UPS and cooling systems. B. ISO 9001 Certification: The manufacturer shall be ISO 9001 & 14001 certified. Certification assures that the vendor’s quality control & environmental measures have been certified by an accredited registrar and meet internationally recognized standards. 1.7. ENVIRONMENTAL REQUIREMENTS A. B. C. D. E. APC by Schneider Electric Storage ambient temperature: Without abbtery: –25°C to 70°C dry heat With battery: –10°C to 45°C Operating ambient temperature: 0°C to 40°C. 15°C to 25°C is ideal for batteries (above the battery lifetime is reduced). Relative humidity: 0 to 95%, non-condensing. Storage elevation: 0 to 15000m. Operating altitude with no de-rating: 0 to 1000m above sea level. 05/2009 edition ch. 6 – spec1 – p. 3 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy Part 2 PRODUCT 2.1. STATIC UPS A. GENERAL 1. 2. 3. 4. 5. 6. B. The UPS shall be housed in a free standing enclosure. The enclosure shall be designed to blend into an IT environment. The cabinet shall be equipped for fork truck lifting. All service and installation access shall be from the front and top The UPS should be able to line up and match and bolt together with other similar kVA and type UPS’ to have the appearance of one entity. The UPS shall be in a self contained cabinet and comprise …[10kVA, 15kVA, 20kVA, 30kVA or 40kVA].. power section; Bypass Static Switch; Battery for standard run time and interface LCD display all mounted in a separate cabinet. The UPS shall permit user installable and removable battery units. The power section shall be of the Double Conversion On-Line topology with power factor corrected input. The UPS shall be sized for ______ kVA and ______ kW load at power factor 0.8. The UPS battery shall be sized for ____ at a power factor of ____ for _____ minutes. SYSTEM INPUT 1. 2. 3. 4. 5. 6. 7. 8. 9. C. Nominal Input voltage rating: 3×400 (adjustable for 3×380 or 3×415) Input Voltage range: 304-477V Earthing principle: [TN-S] [TT] or [IT]. Input frequency: 40-70 Hz (auto sensing) Input power factor: 0.98 for load > 50% Magnetizing inrush current: NONE, if optional input isolating transformer is installed then 500% of nominal input current for less than one cycle Input current distortion with no additional filters. < 5% THD at 100% load Power walk-in/Soft-Start: Shall be linear from 0 to 100% of the load over a 15-second period SYSTEM OUTPUT 1. 2. 3. 4. 5. 6. 7. APC by Schneider Electric Nominal Output voltage rating: 3×400. Earthing principle: [TN-S] [TT] or [IT]. Output voltage regulation for steady state and transient variations (at default parameter settings): a. ± 1% steady state for a static 100% balanced load. b. ± 1% steady state for a static 100% unbalanced load. c. ± 5% for a 0 to 100% load step. Max. Voltage transient recovery time: 100 ms milliseconds to nominal. Output frequency regulation: Synchronized to mains over the range of a. 47-53Hz or 57-63Hz in normal operation. b. 50 Hz ± 0.1 Hz in battery operation. Output voltage harmonic distortion: a. <2% THD maximum and 1% single harmonic for a 100% linear load b. <5% THD maximum for a 100% non-linear load Overload capability: a. 150% for 1 minute in normal operation. b. 125% for 10 minutes in normal operation. c. 110% continuous in bypass operation. d. 800% for 500 milliseconds in bypass operation 05/2009 edition ch. 6 – spec1 – p. 4 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy 8. 9. 10. 11. 12. 13. D. Phase displacement: a. 20 degrees ± 1 degree for balanced load. b. 20 degrees ± 1 degree for 50% unbalanced load. c. 20 degrees ± 3 degrees for 100% unbalanced load. Output Power Factor Rating: For loads exhibiting a power factor of 0.5 leading to 0.5 lagging, no de-rating of the UPS shall be required. Short circuit withstand: The UPS must withstand a bolted-fault short circuit on the output without damage to the UPS unit. System AC-to-AC efficiency >95.3% for loads greater than 100% of system load. System AC-to-AC efficiency >94% for loads greater than 50% of system load. Acoustical noise: dB(A) of noise, typically, measured at 1 meter from the operator surface: a. < 52dBA - 10kVA – 20kVA b. < 55dBA - 30kVA – 40kVA COMPONENTS 1. Rectifier a. Each UPS unit shall include an active power factor corrected rectifier. b. DC bus voltage shall be ±192Vdc nominal. c. The battery charging shall keep the DC bus float voltage of ±220v, ±1% d. The DC buss voltage shall be compensated against temperature variations (Battery Temperature Compensation) to always maintain optimal battery float charging voltage for temperature excursions above or below 25°C. Temperature compensation rate shall be 320mV/°C for ambient temperatures > 2 0°C and 0mV/°C for ambient temperatures < 20°C. e. DC ripple voltage shall be less than ±1% of nominal with no battery connected. f. Input power factor shall be 0.98 lagging at 100% load with out the use of passive filters. Rectifier shall employ electronic waveform control technology to maintain the current sinusoidal. g. Pulse Width Modulation (PWM) current control shall be used. Digital Signal Processors (DSP) shall be used for all monitoring and control tasks. Analogue control is not acceptable. h. Reflected input current Total Harmonic Distortion (THD) shall not exceed 5% at 100% load. i. Input voltage window: 304-477V. 2. Batteries a. Standard battery technology shall be Valve Regulated Lead Acid (VRLA). b. Batteries shall be housed in the same rack as the power section. Batteries shall be modular on pull out shelves for quick replacement and servicing. c. Battery voltage shall be Battery Temperature Compensated as outlined in the rectifier section above. d. End of discharge: ±160Vdc. e. For longer runtimes, external battery frames in the same design should be offered. f. Battery Charge Current Limit: The UPS shall be capable of limiting the energy sourced from the mains for purposes of battery charging. As a default setting, the battery charge energy will be set to 100% of its nominal value. When signalled by a dry contact, (such as from an emergency generator) the UPS shall be capable of limiting the battery charge energy taken from the mains. This shall take place in user selectable increments of 75%, 50%, 25%, 10% and 0% of the nominal charge power. The selection shall be made from the UPS front panel display/control unit. g. The battery charging circuit shall remain active when in Static Bypass and in Normal Operation. 3. Inverter a. The inverter shall consist of fast switching IGBT power module. b. Inverter shall be PWM controlled using DSP logic. Analogue control shall not be acceptable. c. The inverters shall be rated for an output power factor at 0.8. d. Nominal output voltage shall be 3×400 and adjustable for 3×380 or 3×415, 50Hz, L1,L2,L3,N,PE. APC by Schneider Electric 05/2009 edition ch. 6 – spec1 – p. 5 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy e. Efficiency of each inverter at full load: Not less than • 10kVA 94.5% • 15kVA 95.8% • 20kVA 95.5% • 30kVA 95.8% • 40kVA 95.6% f. Output Voltage Total Harmonic Distortion at full load: • Less than 2% for 100% resistive load. • Less than 5% for computer load as defined by EN50091-3/IEC 62040-3. g. Output voltage regulation • Static: Less than 1% at full linear load. • Dynamic: 5% at 100% step load. h. Output frequency: 50Hz free running. i. Crest factor: Unlimited but regulates it down to 2.7. j. Remote Emergency Power Off (EPO) shall be standard (wall switch and wiring shall be provided by the electrical contractor). 4. Static Bypass Switch a. The static switch shall consist of fully rated Silicon Controlled Rectifiers (SCRs). Part rated SCRs with a wrap around contactor are not acceptable. b. The static bypass switch shall automatically transfer the critical load to bypass input supply without interruption after the logic senses one of the following conditions: • Inverter overload beyond rating. • Battery runtime expired and bypass available. • Inverter failure. • Fatal error in control system. c. The static bypass switch shall automatically retransfer from bypass to the inverter, when one of the following conditions occurs: • After an instantaneous overload-induced transfer has occurred and the load current has returned to less than 100% of the system rating. • The inverter is active (on). d. The static bypass switch shall be equipped with a manual means of transferring the load to bypass and back to inverter. e. If more than 10 transfers from and to inverter occur in a 10 minutes period, the load shall be locked on static bypass. An alarm communicating this condition shall be annunciated. E. MECHANICAL 1. Design a. The UPS power section, Static Bypass Switch, internal manual bypass switch and the VRLA batteries shall be housed in a free standing enclosure having the following specifications: • Caster fitted for mobility. Levelling feet shall be supplied as standard. • Cable entry shall be from the bottom on the back of the UPS. • The SUVT UPS enclosure shall meet an ingress level of min. IP20. 2. UPS unit dimensions: Height×Width×Depth [Choose one, depending on UPS kVA and required backup time:] 10 to 20 kVA 30 to 40 kVA APC by Schneider Electric 1500 x (352/523) x 838 mm 1500 x 523 x 838 mm 05/2009 edition ch. 6 – spec1 – p. 6 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy F. DISPLAY, CONTROLS AND ALARMS 1. A microprocessor controlled display unit shall be located on the front of the system. The diplay shall consist of an alphanumeric display with backlight, an alarm LED, and a keypad consist ing of pushbutton switches. 2. The following metered data, shall be available on the alphanumeric display: a. Year, Month, Day, Hour, Minute, Second of occurring events b. Input AC Voltage c. Output AC voltage d. Output AC current e. Input Frequency f. Battery voltage g. Highest Internal Battery temperature 3. The display unit shall allow the user to display an event log of all active alarms and of the 64 most recent status and alarm events. The following minimum set of alarm conditions shall be available: a. Static bypass switch on b. EPO Active c. Mechanical bypass activated d. External bypass switch (Q3) activated e. Battery discharged f. Return from low battery g. Low battery h. Load not powered from UPS i. UPS in bypass j. Runtime calibration aborted k. Runtime calibration started l. Runtime calibration complete m. Battery self test aborted n. Battery self test started o. Battery self test completed p. Number of battery modules decreased q. Number of battery modules increased r. Fan fault s. SBS fault t. System not in sync. u. Bypass not available, frequency/voltage out of range v. Mains voltage/frequency out of range w. Site wiring fault x. Low battery voltage shut down y. XR battery breaker or fuse open z. Defective battery detected aa. Runtime is below alarm threshold bb. Load is above alarm threshold cc. Battery over-voltage warning dd. Battery over-temperature warning ee. Emergency power supply fault ff. Output overloaded 4. The following controls or programming functions shall be accomplished by use of the display unit. Pushbutton membrane switches shall facilitate these operations. a. Silence audible Alarm b. Set the alphanumeric display language c. Display or set the date and time d. Enable or disable the automatic restart feature e. Transfer critical load to and from static bypass f. Test battery condition on demand g. Set intervals for automatic battery tests h. Adjust set points for different alarms i. Program the parameters for remote shutdown. APC by Schneider Electric 05/2009 edition ch. 6 – spec1 – p. 7 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy 5. The following shall make up the UPS front panel user interface. a. UPS output • On Battery: When Yellow, this LED indicates the UPS is running from Battery power • Bypass: When Yellow, this LED indicates the load is being supported by static bypass/mechanical bypass • Fault: When Red, this LED indicates there is a fault condition present in the UPS. b. Push Button User Controls • Up Arrow • Down Arrow • Help Key • Escape Key • Enter Key 6. Potential Free (Dry) Contacts a. The following potential free contacts shall be available on an optional relay interface board: • Normal Operation • Battery Operation • Bypass Operation • Common Fault • Low Battery • UPS Off 7. For purposes of remote communications with the UPS the following shall be available and contained within the UPS on a removable, “hot swappable” “smart slot” interface card: a. RJ-45 Interface port for remote communications with a network via web browser or SNMP. b. Environmental monitoring feature, capable of locally monitoring temperature and humidity as well as one additional generic set of user determined dry contacts capable of taking an input signal from any on/off signal, such as water detection, smoke detection, motion, or fire detection. G. BATTERY 1. 2. APC by Schneider Electric The UPS battery shall be of modular construction made up of user replaceable, hot swappable, fused, battery modules. Each battery module shall be monitored to determine the highest battery unit temperature for use by the UPS battery diagnostic, and temperature compensated charger circuitry. The battery blocks housed within each removable battery module shall be of the Valve Regulated Lead Acid (VRLA) type. 05/2009 edition ch. 6 – spec1 – p. 8 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy Part 3 ACCESSORIES A. EXTENDED RUNTIME (XR) OPTION 1. 2. For purposes of extending the UPS battery runtime, external extended runtime options shall be available. The extended runtime option shall be housed in “line up and match” type enclosures and shall contain necessary hardware and cables to connect to the UPS, or between XR enclosures. Each XR enclosure shall be equipped with removable, hot swappable, battery units housed in draw-out cartridges. The extended runtime system shall have a 250 VDC rated, thermal magnetic trip moulded case circuit breaker (MCCB). Each circuit breaker shall be equipped with shunt trip mechanisms and 1 NO/NC auxiliary contacts. The circuit breakers are to be equipped as part of a line-up-and-match type battery enclosure. B. MAINTENANCE BYPASS PANEL (MBP) 1. 2. 3. 4. 5. 6. 7. 8. A MBP should be offered as a standard option either for single unit or parallel configurations. The maintenance bypass panel shall provide power to the critical load bus from the bypass source, during times where maintenance or service of the UPS system is required. The MBP shall provide a mechanical means of complete isolation of the UPS system from the mains supply. The MBP shall be constructed in a free-standing or wall-mounted IP20 enclosure unless otherwise stated in this specification. As a minimum, the MBP shall contain the following features and accessories: Current limiting breakers of the appropriate size – limiting the short circuit level to max. Isc = 30 kA for the system. Minimum 1 NO/NC auxiliary contact per unit in the parallel system for the purpose of relaying status information of the manual maintenance bypass switch to the UPS. In the case of parallel operation sufficient CAN bus PCB’s to provide adequate communications of the MBP status to the UPS system parallel control system. CE marked according to at least EN/IEC60439. The MBP shall be made to Form 3b The MBP shall be made to IP2XC C. PARALLEL OPERATION 1. 2. 3. For purposes of paralleling UPS units in the event of increased capacity or redundancy, the UPS shall contain as a standard feature, the ability to parallel up to 4 units. In this mode of operation the output voltage, output frequency, output phase angle, and output impedance of each unit shall operate in uniformity to ensure correct load sharing. This control function shall not require any additional footprint and shall be an integral function of each UPS. Multi-drop Bus Network: Communication between units shall be connected in a multi-drop bus network comprising two parallel redundant busses so that the removal of any single cable shall not jeopardize the integrity of the parallel communication system. Load Sharing: A load sharing circuit shall be incorporated into the parallel control circuits to ensure that under no load conditions, no circulating current exists between units. This feature also allows each UPS to share equal amounts of the total critical load bus. Load sharing communications shall be galvanically isolated for purposes of fault tolerance between UPS units. A UPS unit's influence over load sharing shall be inhibited in any mode where the UPS inverter is not supporting its output bus. D. SOFTWARE AND CONNECTIVITY 1. 2. 3. APC by Schneider Electric The Ethernet Web/SNMP Adaptor shall allow one or more network management systems (NMS) to monitor and manage the UPS in TCP/IP network environments. The management information base (MIB) shall be provided in DOS and UNIX "tar" formats. The SNMP interface adaptor shall be connected to the UPS via the RS232 serial port on the standard communication interface board. Unattended Shutdown The UPS, in conjunction with a network interface card, shall be capable of gracefully shutting down one or more operating systems during when the UPS is on reserve mode. 05/2009 edition ch. 6 – spec1 – p. 9 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy 4. E. The UPS shall also be capable of using an RS232 port to communicate by means of serial communications to gracefully shut down one or more operating systems during an on battery situation. REMOTE UPS MONITORING The following three methods of remote UPS monitoring shall be available: 1. 2. 3. F. Web Monitoring: Remote monitoring shall be available via a web browser such as Internet Explorer. RS232 Monitoring: Remote UPS monitoring shall be possible via either RS232 or contact closure signals from the UPS. Simple Network Management Protocol (SNMP): Remote UPS Monitoring shall be possible through a standard MIB II compliant platform. SOFTWARE COMPATIBILITY The UPS manufacturer shall have available software to support graceful shutdown and or remote monitoring for the following systems: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. APC by Schneider Electric Microsoft Windows 95/98/XP Microsoft Windows NT 4.0 SP6/2000 OS/2 Netware 3.2 – 5.1 MAC OS 9.04, 9.22, 10 Digital Unix/True 64 SGI 6.0-6.5 SCO UNIX SVR4 2.3, 2.41 SCO Unix Ware 7.0 - 7.11 SUN Solaris 2.6-2.8 SUN OS 4.13, 4.14 IBM AIX 4.3x-4.33g, 5.1 HP-UX 9.x-11.i 05/2009 edition ch. 6 – spec1 – p. 10 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy Part 4 EXECUTION A. FACTORY ASSISTED START-UP If a factory assisted UPS start-up is requested, factory trained service personnel shall perform the following inspections, test procedures, and on-site training: 1. Visual Inspection: • Inspect equipment for signs of damage. • Verify installation per manufacturer’s instructions. • Inspect cabinets for foreign objects. • Inspect Battery Units. • Inspect Power Module(s). 2. Mechanical Inspection: • Check all UPS and external maintenance bypass cabinet internal power wiring connections. • Check all UPS and external maintenance bypass cabinet terminal screws, nuts, and/or spade lugs for tightness. 3. Electrical Inspection: • Verify correct input and bypass voltage. • Verify correct phase rotation of all mains connections. • Verify correct UPS control wiring and terminations. • Verify voltage of all battery modules. • Verify neutral and ground conductors are properly landed. • Inspect external maintenance bypass switch for proper terminations and phasing. 4. Site Testing: • • • • • • • • • Ensure proper system start-up. Verify proper firmware control functions. Verify proper firmware bypass operation. Verify proper maintenance bypass switch operation. Verify system set points. Verify proper inverter operation and regulation circuits. Simulate utility power failure. Verify proper charger operation. Document, sign, and date all test results. 5. On-Site Operational Training: During the factory assisted start-up, operational training for site personnel shall include • key pad operation • LED indicators • start-up and shutdown procedures • Maintenance Bypass Panel operation • Battery breaker operation • Alarm information. B. MANUFACTURER FIELD SERVICE 1. Worldwide service: The UPS manufacturer shall have a worldwide service organization available, consisting of factory trained field service personnel to perform start-up, prevent tive maintenance, and service of the UPS system and power equipment. The service organization shall offer 24 hours a day, 7 days a week, 365 days a year service support. APC by Schneider Electric 05/2009 edition ch. 6 – spec1 – p. 11 Specification guide no. 1 Single/parallel UPS system, three-phase, 10 to 40/160 kVA* * Maximum power rating without redundancy 2. Replacement parts: Parts shall be available through the worldwide service organization 24 hours a day, 7 days a week, and 365 days a year. The worldwide service organization shall be capable of shipping parts within 4 working hours or on the next available flight, so that the parts may be delivered to the customer site within 24 hours. C. MAINTENANCE CONTRACTS 1. A complete offering of preventative and full service maintenance contracts for the UPS sytem and the battery system shall be available. All contract work shall be performed by factory trained service personnel. D. TRAINING 1. UPS service training workshop: A UPS service training workshop shall be available from the UPS manufacturer. The service training workshop shall include a combination of lecture and practical instruction with hands-on laboratory sessions. The service training workshop shall include instruction about safety procedures, UPS operational theory, sub-assembly identify cation and operation, system controls and adjustment, preventative maintenance, and trou bleshooting. APC by Schneider Electric 05/2009 edition ch. 6 – spec1 – p. 12 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA Contents 1 - UPS definition ............................................................................................................................... 2 1.1 - Purpose .............................................................................................................................. 2 1.2 - Brief description .................................................................................................................. 2 2 - Operating principle ...................................................................................................................... 2 2.1 - Normal operation ................................................................................................................ 2 2.2 - Operation on battery power ................................................................................................ 2 2.3 - Battery recharge ................................................................................................................. 2 2.4 - Transfer to bypass AC source ............................................................................................ 3 2.5 - UPS maintenance ............................................................................................................... 3 2.6 - Battery maintenance ........................................................................................................... 3 2.7 - Cold start (AC power absent) .............................................................................................. 3 3 - Sizing and general characteristics ............................................................................................. 3 3.1 - Technology ......................................................................................................................... 3 3.2 - Rating ................................................................................................................................. 3 3.3 - Battery backup time ............................................................................................................ 3 3.4 - Types of loads accepted ..................................................................................................... 3 3.5 - Limitation of harmonics upstream of the UPS ..................................................................... 4 3.6 - Efficiency ............................................................................................................................ 4 3.7 - Noise level .......................................................................................................................... 4 4 - AC sources ................................................................................................................................... 4 4.1 - Normal AC source .............................................................................................................. 4 4.2 - Bypass AC source .............................................................................................................. 4 5 - Electrical characteristics ............................................................................................................. 4 5.1 - Rectifier and charger........................................................................................................... 4 5.2 - Batteries.............................................................................................................................. 5 5.3 - Inverter................................................................................................................................ 5 5.4 - Static bypass ...................................................................................................................... 6 5.5 - Discrimination and short circuit capacity ............................................................................. 6 5.6 - System earthing arrangement ............................................................................................. 6 6 - Mechanical characteristics .......................................................................................................... 7 6.1 - Mechanical structure ........................................................................................................... 7 6.2 - Scalable design .................................................................................................................. 7 6.3 - Dimensions ......................................................................................................................... 7 6.4 - Connections ........................................................................................................................ 7 6.5 - Safety.................................................................................................................................. 7 7 - Environment conditions .............................................................................................................. 7 7.1 - UPS (not including battery) ................................................................................................. 7 8 - Protection ..................................................................................................................................... 8 8.1 - UPS .................................................................................................................................... 8 8.2 - Rectifier/chargers ................................................................................................................ 8 8.3 - Inverters .............................................................................................................................. 8 8.4 - Batteries.............................................................................................................................. 8 9 - Battery management .................................................................................................................... 8 9.1 - Battery meter ...................................................................................................................... 8 9.2 - Digital battery management ................................................................................................ 9 9.1 - Block by block monitoring ................................................................................................... 9 10 - User interface and communication........................................................................................... 9 10.1 - User interface ................................................................................................................... 9 10.2 - Communication ................................................................................................................. 10 11 - Maintainability ............................................................................................................................ 11 11.1 - Local and remote diagnostics and monitoring - E. Services ............................................. 11 12 - Standards and tests .................................................................................................................. 11 12.1 - Standards ......................................................................................................................... 11 12.2 - Certification of conformity ................................................................................................. 11 13 - Services ...................................................................................................................................... 12 13.1 - Maintenance ..................................................................................................................... 12 13.2 - Technical competency ...................................................................................................... 12 13.3 - Functional components ..................................................................................................... 12 13.4 - System start-up ................................................................................................................. 12 13.5 - Replacement parts ............................................................................................................ 12 13.6 - Recycling and renovation.................................................................................................. 12 14 - Warranty...................................................................................................................................... 12 15 - Installation services ................................................................................................................... 13 16 - Electrical diagram ...................................................................................................................... 13 Appendix. Check list ......................................................................................................................... 14 APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.1 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 1 - UPS definition 1.1 - Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying, putting into operation and maintaining an Uninterruptible Power Supply (referred to as a UPS in the rest of this document). The UPS shall be designed to supply dependable electric power to: For information purposes MTBF in hours Single-UPS unit with static bypass 475 000 Non availability 2.1x10-5 1.2 - Brief description The UPS shall be a single-UPS unit, operating in double-conversion mode (also called on-line mode); it shall be a VFI-type UPS (as per standard IEC 62040-2), made up of the following components, described in detail in this specification: ● PFC rectifier; ● battery charger; ● inverter; ● battery; ● static bypass (via a static switch); ● manual maintenance bypass; ● user and communications interface; ● battery management system; ● any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. The UPS shall ensure continuity of electric power to the load within the specified tolerances, without interruption upon failure or deterioration of the normal AC source (utility power) for a maximum protection time determined by the capacity of the backup batteries installed. 2 - Operating principle The UPS shall operate in double-conversion mode (also called on-line mode); it shall be a VFI-type UPS (as per standard IEC 62040-2), made up of the following components, described in detail in this specification: 2.1 - Normal operation (normal AC source available) The rectifier supplies the inverter with DC current while the charger simultaneously float charges the battery. The load is continuously supplied with dependable electrical power by the inverter. 2.2 - Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter shall continue to supply the load from battery power without interruption or disturbance, within the limits imposed by the specified battery backup time. 2.3 - Battery recharge (normal AC source restored) When the normal AC source is restored, the rectifier shall again power the inverter, without interruption or disturbance to the load, while the charger automatically recharges the battery. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.2 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 2.4 - Transfer to bypass AC source In the event of an overload exceeding system capabilities or UPS shutdown, the static bypass switch shall instantaneously transfer the load to the bypass AC source without interruption, on the condition that bypass power is available and within tolerances. Transfer of the load back to the UPS-unit output, synchronised with the bypass AC source, shall be automatic or manual. During transfer, the load shall not suffer an outage or disturbance in the supply of power. On request, the UPS system may automatically transfer the load with a micro-interruption if a major fault occurs on the UPS system and if synchronisation with the bypass source has not been established. 2.5 - UPS maintenance For maintenance purposes, the UPS shall include a mechanical maintenance bypass system with one-button operation. For personnel safety during servicing or testing, this system shall be designed to isolate the UPS while continuing to supply power to the load from the bypass AC source. The UPS shall also include a device making it possible to isolate the rectifiers and the chargers from the normal AC source. All electronic components shall be accessible from the front of the UPS. 2.6 - Battery maintenance For safe maintenance on the battery, the system shall include a circuit breaker to isolate the battery from the rectifier, the charger and the inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.7 - Cold start (normal AC source absent) The battery shall be capable of ensuring UPS start-up even if normal AC power is not available and continuing operation within the specified back-up time (start on battery power shall be possible on the condition that the system was already started with AC power present). 3 - Sizing and general characteristics 3.1 - Technology The UPS shall be based on sixpack IGBT technology with built-in thermal monitoring and a free-frequency chopping mode to dynamically optimise efficiency and power quality. 3.2 - Rating The UPS shall be sized to continuously supply a load of…[ 40 / 60 / 80 / 100 / 120 ] kVA. The rated active power must be constant for loads at a power factor (pf) of 0.8 lagging to 0.9 leading. 3.3 - Battery backup time The battery backup time in the event of a normal AC source outage shall be _______ minutes, for a load power factor of 0.8. Battery service life shall be equal to at least …[ 5 / 10 ]…years. It shall be selected and sized correspondingly, for a load power factor of 0.8. 3.4 - Types of loads accepted The UPS shall accept high crest factors (3:1) without derating to ensure correct operation with computer loads. The total harmonic voltage distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU downstream ph/ph and ph/N ≤ 2% for linear loads; ● THDU downstream ph/ph and ph/N ≤ 3 % for non-linear loads. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.3 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 3.5 - Limitation of harmonics upstream of the UPS The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of guide IEC 61000-3-4. As such, the UPS shall have a controlled IGBT input rectifier drawing sinusoidal current. In particular, the UPS shall respect the following characteristics at the normal AC input: ● total harmonic current distortion (THDI) upstream of the rectifier not exceeding: - 3% at full rated load for an RCD (computer) load - 5% from 30% to 100% of the full rated load. ● input power factor (pf) greater than or equal to 0.99. 3.6 - Efficiency Overall efficiency shall be greater than or equal to: ● 92% at full rated load (In); ● 90% at half rated load (In/2); ● 85% at quarter rated load (In/4); ● 97% in ECO mode. 3.7 - Noise level The noise level, measured as per standard ISO 3746, shall be less than: ● 63 dBA 4 - AC sources The UPS shall be designed to receive power from the sources listed below. 4.1 - Normal AC source (rectifier input) The normal AC source supplying the UPS shall, under normal operating conditions, have the following characteristics: ● rated voltage: 340 - 470 V at full rated load, 250 - 470 V at 70% load (or 340 - 470 V with backfeed option) ● number of phases: 3 ph + earth. The neutral is not necessary. ● frequency: 50 or 60 Hz ± 8%. 4.2 - Bypass AC source (static-bypass input, if separate from rectifier input) The bypass AC source shall continue to supply the load, without interruption, if its characteristics remain within voltage tolerances (323 to 470 volts). Outside these tolerances, it shall be possible to supply the load, but in downgraded mode. 5 - Electrical characteristics 5.1 - Rectifier and charger 5.1.1 - Supply The rectifier and charger module shall be supplied via the normal AC input. It must be capable of operating without a neutral (see section 4 "AC sources"). In order to protect the battery and maximise its service life, the charger shall be separate from the rectifier and shall provide the battery with a voltage that is independent of the voltage supplied to the inverter. 5.1.2 - Inrush current A device shall be provided to limit inrush currents. When AC power fails and during genset start, the rectifier shall limit the power drawn to 70% of its rating for ten seconds. The remaining 30% shall be supplied by the battery. 5.1.3 - Input power factor The required level of performance is indicated in section 3.5 "Limitation of harmonics upstream of the UPS". APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.4 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 5.1.4 - Operating mode The standard charger shall be sized to recharge the battery rapidly: a battery with a backup time of…[5 / 10 minutes in less than 11 hours] [15 minutes in less than 13 hours] (following a discharge to Pn/2 to recover 90% of backup time). 5.1.5 - Battery-current limiting For long battery life, an electronic device shall automatically limit the charging current to the maximum value specified by the battery supplier (0.1 x C10 for a sealed lead-acid battery). 5.1.7 - Voltage regulation Rectifier/charger regulation shall take into account the ambient temperature of the battery and shall ensure DC output voltage fluctuations of less than 1% irrespective of load and AC input voltage variations (within the limits specified in section 4.1 “Normal AC source”). 5.2 - Batteries The battery shall be of the sealed lead-acid type, mounted and wired, with a service life of …[ 5 / 10 ]… years. It must be sized to supply, in the event of the normal AC source failure, the rated power of the inverter at a power factor PF of 0.8. ………………………………………………………………………………………………………………………………… ( batteries in the UPS cabinet) To facilitate installation and reduce the overall footprint, it must be possible to lodge the battery in the UPS cabinet. Consequently, backup times of: [ 5 ] minutes for the [ 40 / 60 / 80 ] kVA ratings [ 10 ] minutes for the [ 40 / 60 ] kVA ratings [ 15 ] minutes for the [ 40 ] kVA ratings shall be ensured by batteries installed in the UPS cabinet. ………………………………………………………………………………………………………………………………… ( batteries in a separate cabinet) The battery shall be installed in a cabinet identical in appearance to that of the UPS. The battery shall be sized to ensure continuity in the supply of power to the inverter for at least [ 5 / 10 / 15 / 30 ] minutes for the [ 40 / 60 / 80 / 100 / 120 ] kVA ratings. ………………………………………………………………………………………………………………………………… Sizing calculations shall assume an ambient temperature between 0° C and 40° C The UPS shall include devices to ensure: ● effective battery protection (see section 8.4 "Protection - Battery"); ● battery management (see section 9 "Battery management"). 5.3 - Inverter The inverter shall be sized to supply a rated load of …[ 40 / 60 / 80 / 100 / 120]… kVA at 0.8 pf and shall satisfy the specifications listed below. 5.3.1 - Output voltage ● Rated voltage …[ 380 / 400 / 415 ]… volts rms, adjustable via the user interface (see section 10), within tolerances of +/- 3%. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions The variation in the rated voltage shall be limited to ± 2% for a balanced load between 0 and 100% of the rated power, irrespective of normal AC input and DC voltage levels, within the limits specified in section 4.1 “Normal AC source” and 5.1.4 “Rectifier/charger - Operating modes and DC-voltage levels”. ● Voltage variations for load step changes Output voltage transients shall not exceed ± 1% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 100 milliseconds. 5.3.2 - Output frequency ● Rated frequency - 50 or 60 Hz. ● Variations - ± 0.5 Hz, APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.5 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 5.3.3 - Synchronisation with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions below in section 5.4 "Static-bypass"), the inverter output voltage shall be synchronised with the bypass source voltage whenever possible. To that end, during normal operation, a synchronisation system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within adjustable tolerances of ± 0.5% to ± 8% with respect to the rated frequency). ● Synchronisation with an external source It shall be possible to synchronise with all types of external source. For example, if the bypass source is a generator set, the synchronisation tolerances shall be approximately ± 8% (adjustable) with respect to the rated frequency. ● Autonomous operation following loss of synchronisation with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronisation, regulating its own frequency to within ± 0,1 %. When bypass power returns to within tolerances, the inverter shall automatically resynchronise. ● Variation in frequency per unit time To avoid transmitting to the inverter any excessive frequency variations on the bypass AC source when it is within tolerances, inverter frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s or 2 Hz/s (user defined). 5.3.4 - Overload capacity The UPS shall be capable of supplying for at least: ● 1 minutes a load representing 150% of the rated load; ● 1 second a load representing 210% of the rated load. If necessary, the UPS shall operate as a generator (current limiting) with a peak capacity of 270% for 150 milliseconds, to allow highly disturbed transient operating states (high overloads, very high crest factors, etc.) without transferring the load to the bypass. 5.4 - Static bypass 5.4.1 - Load transfer to the static bypass The UPS shall be equipped with a static bypass comprising a static switch. Instantaneous transfer of the load from the inverter to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.2 "Bypass AC source" and that the inverter is synchronised. Transfer shall take place automatically in the event of a major overload or an internal inverter fault. Manually initiated transfer shall also be possible. If the bypass power is outside the specified tolerances or is not synchronised with the inverter, automatic transfer of the load from the inverter to bypass power shall take place after a calibrated interruption adjustable from 13 to 1000 ms. 5.4.2 - Static-switch protection The static switch shall be equipped with an RC filter for protection against switching overvoltages and lightning strikes. 5.5 - Discrimination and short-circuit capacity If the bypass power is within the tolerances specified in section 4.2 "Bypass AC source" section, the presence of the static switch shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the inverter. To ensure tripping in a selective manner, the available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated inverter current). If the bypass source is outside the specified tolerances, the inverter on its own shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of short-circuit. 5.6 - System earthing arrangement The UPS shall be compatible with the following system earthing arrangements: ● upstream source: …[ TT/ IT / TNS / TNC ]… ● downstream installation: …[ TT/ IT / TNS / TNC ]… If the upstream and downstream earthing arrangements are different, galvanic isolation shall be provided on the static-bypass line. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.6 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 6 - Mechanical characteristics 6.1 - Mechanical structure The UPS and batteries shall be installed in cabinet(s) with a degree of protection IP20 (standard IEC 60529). Access to the subassemblies making up the system shall be exclusively through the front. ………………………………………………………………………………………… 6.2 - Scalable design ( Concerns only UPSs with the battery installed in a separate cabinet) The UPS shall be designed to allow the installed power to be easily increased on site by connection of additional UPS units, either to meet new load requirements or to enhance system availability by introducing redundancy. This transformation shall be possible directly on site, without returning the equipment to the factory and without causing excessive system downtime. ………………………………………………………………………………………… 6.3 – Dimensions The UPS shall require as little floor space as possible. To gain space, it shall be possible to install the UPS with the back to the wall. 6.4 - Connection To facilitate connections, all terminal blocks must be easily accessible from the front when the UPS is installed with the back to the wall. Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible through the bottom for a false floor. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 12 "Standards and tests". The cables shall comply with the standards listed in section 12 "Standards and tests" and be mounted in compliance with the stipulations in section 6.6 "Safety". 6.5 - Safety For the safety of maintenance personnel, the cabinet shall be provided with a manually operated mechanical bypass designed to isolate the rectifier, charger, inverter and static switch while continuing to supply the load from the bypass AC source. It shall be possible to send to the UPS an external EPO order resulting in opening of the battery circuit breaker and the upstream circuit breaker. 7 - Environment conditions 7.1 - UPS (not including battery) 7.1.1 - Operation The UPS, not including the battery, shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: 0° C to +40° C. ● recommended temperature range: +20° C to + 25° C; ● maximum relative humidity: 95% at 25° C; ● maximum altitude: 1000 meters. 7.1.2 - Storage The UPS, not including the battery, shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.7 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 8 - Protection 8.1 - UPS The UPS shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2 - Rectifier and charger The rectifier and charger shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer or if the temperature exceeds the limits specified above. 8.3 - Inverter Inverters shall self-protect against overloads and short-circuits, irrespective of the operating mode (AC power or battery power). 8.4 - Batteries 8.4.1 - Protection against deep discharge and self-discharge The UPS shall comprise a device designed to protect the battery against deep discharges, taking into account the characteristics of the discharge cycles, with isolation of the battery by a circuit breaker. 8.4.2 - Independent regulation and monitoring systems A regulation system shall regulate the battery voltage and the charge current. A second system, independent of the regulation, shall monitor the battery voltage and the charge current. Consequently, if the regulation system fails, the monitoring system steps in to shut down the charger and avoid overcharging. 8.4.3 - Regulation of the battery voltage depending on the ambient temperature A temperature sensor adapts the charge voltage to the ambient temperature. This regulation system takes into account the chemical reaction and prolongs the battery service life. The permissible temperature range is set in the personalisation parameters. An alarm shall be issued for temperatures outside the permissible range. 8.4.4 - Self-test Battery monitoring shall be carried out by an automatic device. Self-test intervals shall be set to one month by default, but shall be adjustable. This self-test system shall, where necessary, initiate indications via LEDs on the front panel or a message to a remote monitoring system. 8.4.5 - Possibility of backfeed protection If backfeed protection is necessary, it must be possible to install two independent systems on the normal and bypass AC inputs. 8.4.6 - Possibility of battery circuit-breaker management The UPS shall be capable of receiving and managing two battery circuit breakers. Battery availability is improved by dividing it into two sections. If one section is disconnected for servicing or any other reason, the second shall remain available and provide approximately half of the backup time.In such a case, the UPS shall regulate the charge accordingly. 9 - Battery management 9.1 - Battery meter A battery-meter function shall estimate the available backup time as a function of the battery charge and the percent load. It shall be possible to set the battery meter so that it can take into account the exact battery configuration installed with the UPS. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.8 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 9.2 - Digital battery monitoring The UPS shall be equipped with a system for battery digital management. Based on a number of parameters (percent load, temperature, battery type and age), the system shall control the battery charge voltage and continuously calculate: ● The true available backup time ● The remaining service life. 9.3 - Block by block monitoring To further optimise battery availability and service life, it shall be possible to equip the UPS with an optional system to continuously monitor all battery strings and display a block by block failure prediction. The system shall include the functions listed below. ● Continuous measurement of the voltage of each block. ● Continuous measurement of the internal resistance. ● Identification of faulty blocks (trend curves). ● Possibility of replacing individual blocks. ● Remoting of all information via Ethernet, dry contacts or JBus. 10 - User interface and communication 10.1 - User interface UPS operation shall be facilitated by a user interface comprising: ● a graphic display (at least quarter VGA and high resolution are preferable); ● controls; ● status indications with mimic panel. 10.1.1 - Graphic display The graphic display shall facilitate operation by offering the functions listed below. ● operating language It shall be possible to display in the _________________ language all the operating information supplied on the screens. ● step by step operating help The graphic display shall assist the user by providing step by step help in the user's language. ● animated colour mimic diagram The mimic diagram shall enable display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass). ● display of measurements It shall be possible to display the following measurements: - inverter output phase-to-phase voltages; - inverter output currents; - inverter output frequency; - voltage across battery terminals; - battery charge or discharge current; - rectifier/charger input phase-to-phase voltages; - rectifier/charger input currents; - crest factor; - active and apparent power; - power factor of the load; - battery temperature. ● display of status conditions and events It shall be possible to display the following indications: - load on battery power; - load on UPS; - load on automatic bypass; - general alarm; - battery fault; - remaining battery backup time; - low battery warning; - bypass AC source outside tolerances; - battery temperature. Additional information shall be provided in view of accelerating servicing of the system, as specified in section 11 “Maintainability”. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.9 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) ● display of operating graphs It shall be possible to graphically display the measurements mentioned above on the screen over significant periods. ● log of time-stamped events This function shall store in memory and make available, for automatic or manually initiated recall, time-stamped logs of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. It shall be possible to time stamp and store at least 2 000 events. 10.1.2 - Controls The UPS shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of the UPS, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● EPO terminal block The UPS shall be equipped with an emergency power off terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of UPS units; - opening of the static switch on the bypass line and of the battery circuit breaker; - opening of an isolated dry contact on the programmable card. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. 10.1.3 - Status indications with mimic panel Indication of status conditions shall be distinct of the graphic display. Three LEDs on the control panel indicate the following status conditions: ● load protected; ● minor fault; ● major fault. The mimic panel shall represent the UPS and indicate the status of the load supply using five two-colour (red and green) LEDs: ● load supplied (LED at UPS output on mimic panel), ● inverter on (inverter LED on mimic panel), ● operation on battery power (LED between battery and inverter on mimic panel), ● bypass activated (bypass LED on mimic panel), ● PFC rectifier on (rectifier LED on mimic panel). A buzzer shall warn the user of faults, malfunctions or operation on battery power. 10.2 - Communication 10.2.1 - Standard communication It shall be possible to remote the following controls, indications and measurements. To that end, the UPS shall have as standard equipment: ● a programmable card for input/output information. This card shall provide a total of eight dry contacts: six for incoming information and two for outgoing information. ● at least three communication ports for later addition, without interrupting operation, of communication cards implementing different protocols, e.g. SNMP, JBus/ModBus, RS232, USB. 10.2.2 - Communications options The UPS shall be designed to enable the extension of communications, without system shutdown, to the following types of cards: ● an SNMP communication card for connection to an Ethernet network, for connection to a computer-network management system; ● an RS485 serial-link communication card capable of implementing the JBus/ModBus protocol for connection to a building management system (BMS); ● an RS232 serial-link communication card for communication with a modem and a remote-maintenance system; ● a USB communication card; ● an XML-Web communication card for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser. The UPS shall be detectable by supervision software for large UPS systems. Shutdown and administration software shall be available in addition to the communication cards. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.10 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 11 - Maintainability For optimum safety during servicing, a maintenance bypass shall be available to completely isolate the UPS. 11.1 - Local and remote diagnostics and monitoring - E. Services The UPS shall be equipped with a self-test system to check operation of the system as a whole each time it is started. To that end, the supply control/monitoring electronics shall offer: ● auto-compensation of component drift; ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote); ● overall readiness for remote supervision services provided by the manufacturer. 12 - Standards and tests 12.1 - Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. ● IEC 6014A-4: UPS - Performance. ● IEC 62040-1 and EN 62040-1: UPS - Safety. ● IEC 62040-2 and EN 62040-2: UPS - Electromagnetic compatibility - [level C3 / C2 class A is optional]. ● IEC 62040-3 and EN 62040-3: UPS - Performance. ● IEC 60950 / EN 60950: Safety of IT equipment, including electrical business equipment. ● IEC 61000-2-2: Compatibility levels for low-frequency conducted disturbances and signalling in public lowvoltage power supply systems. ● IEC 61000-4: EMC - Electrical fast transient/burst immunity. ● IEC 439: Low-voltage switchgear and controlgear assemblies. ● IEC 60529: Degrees of protection provided by enclosures (IP Code). ● ISO 3746: Sound power levels. ● CE marking. What is more, the equipment must comply with environmental-protection standards, with production taking place on premises certified ISO 14001. The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. 12.2 - Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.11 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 13 - Services 13.1 - Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 13.2 - Technical competency ● customer operators: the supplier shall offer a level 2 training program. ● service personnel: the supplier shall ensure that service personnel are qualified for level 4. 13.3 - Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorised agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). 13.4 - System start-up ● The system and equipment shall be started up on site by the supplier or its authorised agent. The procedure shall include checks on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. 13.5 - Replacement parts ● The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 13.6 Recycling and renovation/substitution ● At the end of the UPS service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 14 - Warranty The rectifier/charger and inverter subassemblies shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.12 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) 15 - Installation services Required services include: ● supply of the UPS and any accessory parts or elements; ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site; ● connections between the battery and the UPS; ● connection of the normal AC source to the rectifier/charger; ● connection of the bypass AC source to the input transformer or bypass input; ● connection of the load circuits to the UPS output. 16 - Electrical diagram Fig.: UPS electrical diagram. APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.13 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) Appendix. Check list Type of UPS Total rated power (kVA) at PF 0.8 kVA Manufacturer Range of products yes no yes no yes no 342 - 470 V yes no 250 - 470 V yes no constant for loads with cos ϕ 0.8 lagging to cos ϕ 0.9 leading yes no Sixpack IGBT converter with built-in thermal monitoring yes no Sinusoidal current drawn (PFC) yes no Operating mode (IEC 62040-2) double conversion Continuous operation at 40 °C Parallel connection ≤ 6 modules without interrupting operation kVA max. Rectifiers Three-phase input voltage at Pn at 0.70 Pn Rated active power sinusoidal input current THDI upstream ≤ 3% yes no in phase with the voltage PF > 0.99 yes no THDI, PF performance constant from 30 to 100% of Pn yes no 45 - 65 Hz yes no No inrush or start-up current yes no Charger independent with respect to rectifier yes no Frequency Rapid battery charger Backup time 10 minutes in t ≤ 11 hours, 4 hours in t ≤ 24 hours yes no Voltage regulation ±1% yes no yes no yes no yes no Independent regulation/monitoring systems Battery Type standard sealed lead acid in a cabinet other Service life years yes no Backup time minutes yes no Automatic entry of battery parameters yes no Temperature correction yes no yes no yes no yes no Battery management and protection Measurement of actual backup time, depending on: load, temperature, age Cold start on battery power Protection against deep discharge APC by Schneider Electric with circuit-breaker opening 05/2009 edition ch.6 - spec. 2a – p.14 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) yes no yes no Self-tests yes no Battery meter yes no Block by block monitoring yes no yes no yes no Management of 2 battery circuit breakers Charge-current limiting 0.05 C10 to 0.1 C10 (depending on battery) Inverter Sixpack IGBT inverter with built-in thermal monitoring Volts Three-phase output voltage with neutral Compensation Adjustable line drop 0 to ± 5% yes no Steady-state conditions ± 1% yes no Voltage transients ± 2% (load from 0 to 100 or 100 to 0 %) yes no Output voltage distortion at Pn THDU ph-N < 2% for linear loads yes no THDU ph-N < 3% for non-linear loads yes no yes no yes no Frequency synchronisation with an external ± 8 % of rated frequency source yes no Overload capacity 150% In for 1 minutes yes no 210% In for 1 second yes no Current limiting 270% In for 150 milliseconds yes no Crest factor up to 3:1 yes no yes no 45 In at 20 kVA / 19 In at 120 kVA - 20 ms yes no yes no Hz Output frequency Variation in output frequency ± 0.5 Hz Static bypass Static bypass Short-circuit withstand of static bypass Maintenance bypass Efficiency Normal mode > 92% at Pn, > 90 % at Pn/2 yes no ECO mode > 97% at Pn yes no selection of operating language yes no personalisation menu with password yes no display measurements, status, events, graphs yes no event log Time-stamping yes no Controls ON, OFF, EPO terminal block yes no Status indications with mimic panel Audio alarm, LEDs yes no User interface Graphic display in 15 languages APC by Schneider Electric 05/2009 edition ch.6 - spec. 2a – p.15 Specification guide no. 2a Single UPS, three-phase, 40 to 120 kVA (cont.) Communication Programmable relay card yes no EPO terminal block yes no 3 slots for communication cards yes no Options Ethernet SNMP card yes no RS485 JBus/ModBus card yes no RS232 U-Talk card yes no XML-Web card yes no Supervision software yes no with shutdown management yes no Certified standards and tests See list in section 12.1 yes no Certification of performance TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier Level 4 NFX 060-010 yes no Diagnostics and monitoring Remote yes no Technical support International yes no yes no yes no yes no yes no Administration software Certification Services Operation, Maintainability Access to power components through front Access to communication through front hot-swap cards Access to batteries through front Availability Availability of original replacement parts Around the world t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes yes no no Emergency services yes no Renovation / substitution programmes yes no Maintenance programmes APC by Schneider Electric Preventive Predictive 05/2009 edition ch.6 - spec. 2a – p.16 Specification guide no. 2b Parallel UPS, three-phase, 40 to 720 kVA* * Maximum power rating without redundancy Contents 1 - UPS definition 1.1 - Purpose .............................................................................................................................. 2 1.2 - Brief description .................................................................................................................. 2 2 - Operating principle ...................................................................................................................... 2 2.1 - Normal operation ................................................................................................................ 2 2.2 - Operation on battery power ................................................................................................ 2 2.3 - Battery recharge ................................................................................................................. 3 2.4 - Parallel operation and redundancy ..................................................................................... 3 2.5 - Transfer to bypass AC source ............................................................................................ 3 2.6 - Maintenance on UPS units ................................................................................................. 3 2.7 - Battery maintenance ........................................................................................................... 3 2.8 - Cold start (AC power absent) .............................................................................................. 3 3 - Sizing and general characteristics ............................................................................................. 4 3.1 - Technology ......................................................................................................................... 4 3.2 - Rating ................................................................................................................................. 4 3.3 - Battery backup time ............................................................................................................ 4 3.4 - Reliability and MTBF ........................................................................................................... 4 3.5 - Types of loads accepted ..................................................................................................... 4 3.6 - Limitation of harmonics upstream of the UPS ..................................................................... 4 3.7 - Efficiency ............................................................................................................................ 4 3.8 - Noise level .......................................................................................................................... 4 4 - AC sources ................................................................................................................................... 5 4.1 - Normal AC source .............................................................................................................. 5 4.2 - Bypass AC source .............................................................................................................. 5 5 - Electrical characteristics ............................................................................................................. 5 5.1 - Rectifiers and chargers ....................................................................................................... 5 5.2 - Batteries.............................................................................................................................. 5 5.3 - Inverters .............................................................................................................................. 6 5.4 - Static-bypass function ......................................................................................................... 7 5.5 - Discrimination and short-circuit capacity ............................................................................. 7 5.6 - System earthing arrangement ............................................................................................. 7 6 - Mechanical characteristics .......................................................................................................... 8 6.1 - Mechanical structure ........................................................................................................... 8 6.2 - Scalable design .................................................................................................................. 8 6.3 - Dimensions ......................................................................................................................... 8 6.4 - Connections ........................................................................................................................ 8 6.5 - Safety.................................................................................................................................. 8 7 - Environment conditions .............................................................................................................. 8 7.1 - UPS (not including battery) ................................................................................................. 8 8 - Protection ..................................................................................................................................... 9 8.1 - UPS .................................................................................................................................... 9 8.2 - Rectifier/chargers ................................................................................................................ 9 8.3 - Inverters .............................................................................................................................. 9 8.4 - Batteries.............................................................................................................................. 9 9 - Battery management .................................................................................................................... 10 9.1 - Battery meter ...................................................................................................................... 10 9.2 - Digital battery management ................................................................................................ 10 9.3 - Block by block monitoring ................................................................................................... 10 10 - User interface and communication........................................................................................... 10 10.1 - User interface ................................................................................................................... 10 10.2 - Communication ................................................................................................................. 12 11 - Maintainability ............................................................................................................................ 12 11.1 - Local and remote diagnostics and monitoring - E. Services ............................................. 12 12 - Standards, tests and quality assurance ................................................................................... 12 12.1 - Standards ......................................................................................................................... 12 12.2 - Certification of conformity ................................................................................................. 12 13 - Services ...................................................................................................................................... 13 13.1 - Maintenance ..................................................................................................................... 13 13.2 - Technical competency ...................................................................................................... 13 13.3 - Functional components ..................................................................................................... 13 13.4 - System start-up ................................................................................................................. 13 13.5 - Replacement parts ............................................................................................................ 13 13.6 - Recycling and renovation.................................................................................................. 13 14 - Warranty...................................................................................................................................... 13 15 - Installation services ................................................................................................................... 14 16 - Electrical diagram ...................................................................................................................... 14 Appendix. Check list ......................................................................................................................... 15 APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.1 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 1 - UPS definition 1.1 - Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying, putting into operation and maintaining an Uninterruptible Power Supply system (referred to as a UPS in the rest of this document). The UPS system shall be designed to supply dependable electric power to: For information purposes MTBF in hours Single-UPS unit with static bypass Non availability 475000 2.1x10-5 1.88x106 1.25x106 9.39x105 5.32x10-6 7.98x10-6 1.07x10-5 Active redundancy N+1 - 2 UPS units (1+1) - 3 UPS units (2+1) - 4 UPS units (3+1) The total load supplied by the UPS system shall be equal to .kVA, at a power factor pf = 0.8. 1.2 - Brief description The UPS system shall be made up of …[ 2 / 3 / 4 /5 / 6 ]… identical parallel-connected single-UPS units (same power rating), operating in double-conversion mode (also called on-line mode); it shall be a VFI-type UPS (as per standard IEC 62040-2). Each UPS unit shall have a unit rating of …[ 40 / 60 / 80 / 100 / 120 ]… and shall comprise the following components, described below in this specification: ● PFC rectifier; ● battery charger; ● inverter; ● battery; …………………………………………………………………………………………………………………………………. ( for a system with 2 UPSs in an active redundancy configuration) ● static bypass (via a static switch) for each UPS unit; ● manual maintenance bypass for each UPS unit …………………………………………………………………………………………………………………………………. ( for all other cases) ● an external bypass in an enclosure or cubicle. …………………………………………………………………………………………………………………………………. ● user and communications interface; ● battery management system; ● any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. The UPS system shall ensure continuity of electric power to the load within the specified tolerances, without interruption upon failure or deterioration of the normal AC source (utility power) for a maximum protection time determined by the capacity of the backup batteries installed. . 2 - Operating principle Each single-UPS unit shall operate in double-conversion mode (also called on-line mode); it shall be a VFI-type UPS (as per standard IEC 62040-2), made up of the following components, described in detail in this specification 2.1 - Normal operation (normal AC source available) The rectifier shall supply the corresponding inverter with DC current while the charger simultaneously float charges its battery. The load is continuously supplied with dependable electrical power by the inverter. 2.2 - Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter shall continue to supply the load with power from its battery without interruption or disturbance, within the limits imposed by the specified battery backup time. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.2 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 2.3 - Battery recharge (normal AC source restored) When the normal AC source is restored, the rectifier shall again power the corresponding inverter, without interruption or disturbance to the load, while the charger automatically recharges the battery. The UPS system shall ensure equal sharing of the total load between the various parallel-connected units. 2.4 - Parallel operation and redundancy …………………………………………………………………………………………………………………………………. ( without redundancy) The system shall not be redundant. The …[ 2 / 3 / 4 / 5 / 6 ]… UPS units must operate in parallel to supply the load. Shutdown of a UPS unit shall result in load transfer to the bypass AC source via the various static bypass switches. ………………………………………………………………………………………………………………………………….. ( with redundancy) The units shall operate in parallel with redundancy, with the load shared equally between the units. Redundancy shall be of the "n+1" (or n+2) type, i.e. "1" (or 2) units shall be redundant in the total of n units. If a major fault occurs on a unit, it shall automatically disconnect. If the remaining unit(s) are sufficient to supply the load, it/they shall remain in operation. If the total available power is insufficient, the load shall be automatically transferred, without interruption, to the bypass AC source, if it is within tolerances. …………………………………………………………………………………………………………………………………. 2.5 - Transfer to bypass AC source In the event of an overload exceeding system capabilities (short-circuits, heavy inrush currents, etc.) the load shall be automatically transferred, instantaneously and without interruption, to the bypass AC source, on the condition that bypass power is available and within tolerances. To that end, synchronisation of each inverter in phase and frequency with the bypass source shall be automatic. Transfer of the load back to the UPS-unit outputs shall be automatic or manual. During transfer, the load shall not suffer an outage or disturbance in the supply of power. To ensure transfer in complete safety, the system shall simultaneously control the static switches. On request, the UPS system may automatically transfer the load with a micro-interruption if a major fault occurs on the UPS system and if synchronisation with the bypass source has not been established. 2.6 - Maintenance on UPS units For maintenance purposes, all electronic components shall be accessible from the front of the UPS. In addition, a built-in manually-operated mechanical bypass system shall be: - installed in each UPS unit; ( for a system with 2 UPS units with active redundancy) - installed separately in an external bypass enclosure or cubicle ( other cases). For personnel safety during servicing or testing, this system shall be designed to isolate the UPS units while continuing to supply power to the load from the bypass AC source. Transfer to the manual bypass mode and back shall be possible without interruption to the load. The UPS shall also include a device making it possible to isolate the rectifiers and the chargers from the normal AC source. 2.7 - Battery maintenance For safe maintenance on the battery of each UPS unit, the system shall include a circuit breaker to isolate the battery from the corresponding rectifier/charger and inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.8 - Cold start (normal AC source absent) The battery of each UPS unit shall be capable of ensuring UPS start-up even if normal AC power is not available and continuing operation within the specified back-up time (start on battery power shall be possible on the condition that the system was already started with AC power present). APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.3 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 3 - Sizing and general characteristics 3.1 - Technology The UPS shall be based on sixpack IGBT technology with built-in thermal monitoring and a high free-frequency chopping mode to dynamically optimise efficiency and power quality. 3.2 - Rating The UPS system shall be sized to continuously supply a load of kVA, at a power factor (pf) of 0.8. It shall be made up of ...[ 2 / 3 / 4 / 5 / 6 ]... UPS units, each with an identical rating of ...[ 40 / 60 / 80 / 100 / 120 ]... kVA. The total installed power rating shall thus be kVA. ...[Consequently, 1 (or 2) unit(s) may be redundant.] 3.3 - Battery backup time The backup time of each battery in the event of a normal AC source outage shall be …[ 5 / 10 / 15 / 30 / 60…]… minutes. The service life of each battery shall be equal to at least …[5 / 10]… years. Batteries shall be selected and sized accordingly. ………………………………………………………………………………………………………………………………. 3.4 - Reliability and MTBF The active redundancy type architecture shall allow the installation to reach an MTBF of … [1.88x106 / 1.25x106 / 9.39x105 hours] corresponding to an unavailability of [5.32x10-6 / 7.98x10-6 / 1.07x10-5 ] ………………………………………………………………………………………………………………………………. 3.5 - Types of loads accepted If all the connected loads are non-linear (100% non-linear loads), each UPS unit shall accept high crest factors (3:1) without derating of output. For both linear and non-linear loads, the voltage total harmonic distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU downstream ph/ph and ph/N ≤ 2% for linear loads; ● THDU downstream ph/ph and ph/N ≤ 3% for non-linear loads. 3.6 - Limitation of harmonics upstream of the UPS system The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of guide IEC 61000-3-4 (formerly IEC 1000 3-4). In particular, the UPS shall respect the following characteristics at the normal AC input: ● total harmonic current distortion (THDI) upstream of the rectifier not exceeding: - 3% at full rated load for an RCD (computer) load, at Pn; - 5% from 30% to 100% of the full rated load; ● input power factor (pf) greater than or equal to 0.99. These performance levels, due to the "clean" input rectifier drawing sinusoidal current, limit upstream distortion and avoid oversizing of upstream equipment (cables, circuit breakers, etc.), without requiring additional filters. 3.7 - Efficiency Overall efficiency of each UPS unit shall be greater than or equal to: ● 92% at full rated load (In) in normal mode; ● 90% at 50% rated load (In/2) in normal mode; ● 85% at quarter rated load (In/4); ● 97% in ECO mode. 3.8 - Noise level The noise level, measured as per standard ISO 3746, shall for each unit be less than: ● 63 dBA. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.4 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 4 - AC sources The UPS system shall be designed to receive power from the sources presented below. 4.1 - Normal AC source (rectifier input) The normal AC source supplying the UPS shall, under normal operating conditions, have the following characteristics: ● rated voltage: 340 - 470 V at full rated load, 250 - 470 V at 70% load (or 340 - 470 V with backfeed option) ● number of phases: 3 ph + earth. The neutral is not necessary. ● frequency: 50 or 60 Hz ± 8%. 4.2 - Bypass AC source (static-bypass input, if separate from rectifier input) The bypass AC source shall continue to supply the load, without interruption, if its characteristics remain within voltage tolerances (323 to 470 volts). Outside these tolerances, it shall be possible to supply the load, but in downgraded mode. 5 - Electrical characteristics 5.1 – Rectifiers and chargers 5.1.1 - Supply The rectifier and charger module shall be supplied via the normal AC input. It must be capable of operating without a neutral (see section 4.1). 5.1.2 - Inrush current A device shall be provided to limit inrush currents. When AC power fails and during genset start, the rectifier shall limit the power drawn to 70% of its rating for ten seconds. The remaining 30% shall be supplied by the battery. 5.1.3 - Battery-current limiting For long battery life, an electronic device shall automatically limit the charging current to the maximum value specified by the battery supplier (0.1 x C10 for a sealed lead-acid battery). 5.1.4 - Operating mode The standard charger of each unit shall be sized to recharge the battery rapidly: a battery with a backup time of…[5 / 10 minutes in less than 11 hours] [15 minutes in less than 13 hours]… (following a discharge to Pn/2 to recover 90% of backup time). 5.1.5 - Input power factor The required level of performance is indicated in section 3.5 "Limitation of harmonics upstream of the UPS". 5.1.6 - Voltage regulation Rectifier/charger regulation on each unit shall take into account the ambient temperature of the battery and shall ensure DC output voltage fluctuations of less than 1% irrespective of load and AC input voltage variations (within the limits specified in section 4.1 “Normal AC source”). 5.2 - Batteries Each UPS unit shall be equipped with its own battery of the ………………………………………………………………………………………………………………………………… ( batteries in the UPS cabinet) sealed lead-acid type, with a service life of …[ 5 / 10 ]… years, factory mounted and wired in the UPS cabinet. Battery mounting in the UPS cabinet is intended to facilitate installation and reduce the overall footprint. Consequently, backup times of: [ 5 ] minutes for the [ 40 / 60 / 80 ] kVA ratings [ 10 ] minutes for the [ 40 / 60 ] kVA ratings [ 15 ] minutes for the [ 40 ] kVA ratings shall be ensured by batteries installed in the UPS cabinet. ………………………………………………………………………………………………………………………………… APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.5 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) ( batteries in a separate cabinet) …[sealed lead-acid type, factory mounted and wired in a cabinet identical to that of the UPS,] … [sealed lead-acid type, mounted on shelves,]…[vented lead-acid type, mounted on a rack,]... with a service life of …[5 / 10]… years. The battery shall be installed in a cabinet identical in appearance to that of the UPS. The battery shall be sized to ensure continuity in the supply to the inverter for at least [ 5 / 10 / 15 / 30 ] minutes for a power rating of [ 40 / 60 / 80 / 100 / 120 ] kVA. ………………………………………………………………………………………………………………………………… Each battery shall be sized to ensure continuity in the supply of power to the corresponding inverter for at least …[5 / 10 / 15 / 30 ]… minutes, in the event of a normal AC source failure, with the inverter operating at full rated load, i.e. kVA at a power factor (pf) of 0.8. Sizing calculations shall assume an ambient temperature between 0° C and 40° C. The UPS system shall include devices to ensure: ● effective battery protection (see section 8.4 "Protection - Battery"); ● battery management (see section 9 "Battery management"). 5.3 - Inverters Each inverter shall be sized to supply a load rated …[ 40 / 60 / 80 / 100 / 120 ]… kVA at a power factor (pf) of 0.8, taking into account the characteristics presented below. 5.3.1 - Output voltage ● Rated voltage …[ 380 / 400 / 415 ]… volts rms, adjustable via the user interface (see section 10), within tolerances of +/- 3%. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions The variation in the rated voltage shall be limited to ± 2% for a balanced load between 0 and 100% of the rated power, irrespective of normal AC input and DC voltage levels, within the limits specified in section 4.1 “Normal AC source” ● Voltage variations for load step changes Output voltage transients shall not exceed ± 1% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 100 milliseconds. 5.3.2 - Output frequency ● Rated frequency - 50 or 60 Hz. ● Variations - ± 0.5 Hz, 5.3.3 - Synchronisation with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions below in section 5.4 "Static-bypass"), the inverter output voltage shall be synchronised with the bypass source voltage whenever possible. To that end, during normal operation, a synchronisation system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within adjustable tolerances of ± 0.5% to ± 8% with respect to the rated frequency). ● Synchronisation with an external source It shall be possible to synchronise with all types of external source. For example, if the bypass source is a generator set, the synchronisation tolerances shall be approximately ± 8% (adjustable) with respect to the rated frequency. ● Autonomous operation following loss of synchronisation with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronisation, regulating its own frequency to within ± 0,1%. When bypass power returns to within tolerances, the inverter shall automatically resynchronise. ● Variation in frequency per unit time During the switch to free-running mode and the switch back to synchronised mode, frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s or 2 Hz/s (user defined). APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.6 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 5.3.4 - Overload capacity The UPS shall be capable of supplying for at least: ● 1 minute a load representing 150% of the rated load; ● 1 second a load representing 210% of the rated load. If necessary, the UPS shall operate as a generator (current limiting) with a peak capacity of 270% for 150 milliseconds, to allow highly disturbed transient operating states (high overloads, very high crest factors, etc.) without transferring the load to the bypass. 5.4 - Static-bypass 5.4.1 - Static bypass Each UPS unit shall be equipped with a static bypass comprising a static switch. The static bypasses shall be controlled simultaneously by a built-in system. Instantaneous transfer of the load from the inverters to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.1 "Bypass AC source" and that the inverters are synchronised. Transfer shall take place automatically in the event of a major overload or an internal inverter fault. Manually initiated transfer shall also be possible. If the bypass power is outside the specified tolerances or is not synchronised with the inverter, automatic transfer of the load from the inverter to bypass power shall take place after a calibrated interruption adjustable from 13 to 1000 ms. 5.4.2 - Static-switch protection Each static switch shall be equipped with an RC filter for protection against switching overvoltages and lightning strikes. 5.5 - Discrimination and short-circuit capacity If the bypass power is within the tolerances specified in section 4.1 "Bypass AC source" , the presence of the static switch shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the common inverter output. To ensure tripping in a selective manner, the available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated UPS-system current). If the bypass source is outside the specified tolerances, the UPS system on its own shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of short-circuit. Parallel connection of a number of UPS units significantly improves discrimination. 5.6 - System earthing arrangement The UPS shall be compatible with the following system earthing arrangements: ● upstream source: …[ TT/ IT / TNS / TNC ]… ● downstream installation: …[ TT/ IT / TNS / TNC ]… If the upstream and downstream earthing arrangements are different, galvanic isolation shall be provided on the static-bypass line. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.7 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 6 - Mechanical characteristics 6.1 - Mechanical structure The UPS and batteries shall be installed in cabinet(s) with a degree of protection IP20 (standard IEC 60529). Access to the subassemblies making up the system shall be exclusively through the front. 6.2 - Scalable design [Concerns only UPSs with the battery installed in a separate cabinet] The UPS shall be designed to allow the installed power to be easily increased on site by connection of additional UPS units, either to meet new load requirements or to enhance system availability by introducing redundancy. This transformation shall be possible directly on site, without returning the equipment to the factory and without causing excessive system downtime. 6.3 – Dimensions The UPS shall require as little floor space as possible. To gain space, it shall be possible to install the UPS with the back to the wall. 6.4 - Connection To facilitate connections, all terminal blocks must be easily accessible from the front when the UPS is installed with the back to the wall. Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible through the bottom for a false floor. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 12 "Standards and tests". The cables shall comply with the standards listed in section 12 "Standards and tests" and be mounted in compliance with the stipulations in section 6.6 "Safety". The neutral conductor shall be oversized for any third-order harmonic currents and their multiples (the size of the neutral shall be 1.5 times that of each phase). 6.5 - Safety The equipment shall meet the requirements of degree of protection index IP21, in compliance with standard IEC 60529. For the safety of maintenance personnel, the cabinet shall be provided with a manually operated mechanical bypass designed to isolate the rectifier, charger, inverter and static switch while continuing to supply the load from the bypass AC source. It shall be possible to send to the UPS an external EPO order resulting in opening of the battery circuit breaker and the upstream circuit breaker. 7 - Environment conditions 7.1 - UPS (not including batteries) 7.1.1 - Operation The UPS shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: 0° C to +40° C; ● recommended temperature range: +20° C to + 25° C; ● maximum relative humidity: 95% at 25° C; ● maximum altitude without derating: 1 000 meters. 7.1.2 - Storage The UPS, not including the battery, shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.8 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 8 - Protection 8.1 - UPS Each UPS unit shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2 - Rectifier and charger The rectifier and charger shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer or if the temperature exceeds the limits specified above. 8.3 - Inverter Inverters shall self-protect against overloads and short-circuits, irrespective of the operating mode (AC power or battery power). 8.4 - Batteries 8.4.1 - Protection against deep discharge and self-discharge The UPS shall comprise a device designed to protect the battery against deep discharges, taking into account the characteristics of the discharge cycles, with isolation of the battery by a circuit breaker. 8.4.2 - Independent regulation and monitoring systems A regulation system shall regulate the battery voltage and the charge current. A second system, independent of the regulation, shall monitor the battery voltage and the charge current. Consequently, if the regulation system fails, the monitoring system steps in to shut down the charger and avoid overcharging. 8.4.3 - Regulation of the battery voltage depending on the ambient temperature A temperature sensor adapts the charge voltage to the ambient temperature. This regulation system takes into account the chemical reaction and prolongs the battery service life. The permissible temperature range is set in the personalisation parameters. An alarm shall be issued for temperatures outside the permissible range. 8.4.4 - Self-test Battery monitoring shall be carried out by an automatic device. Self-test intervals shall be set to one month by default, but shall be adjustable. This self-test system shall, where necessary, initiate indications via LEDs on the front panel or a message to a remote monitoring system. 8.4.5 - Possibility of backfeed protection If backfeed protection is necessary, it must be possible to install two independent systems on the normal and bypass AC inputs. 8.4.6 - Possibility of battery circuit-breaker management Each UPS unit shall be capable of receiving and managing two battery circuit breakers. Battery availability is improved by dividing it into two sections. If one section is faulty, the second shall remain available and provide approximately half of the backup time. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.9 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 9 - Battery management 9.1 - Battery meter The battery-meter function estimates the total available backup time of the UPS system as a function of the battery charge and the percent load. It shall be possible to set the battery meter so that it can take into account the exact battery configuration installed with the UPS 9.2 - Digital battery monitoring The UPS shall be equipped with a system for battery digital management. Based on a number of parameters (percent load, temperature, battery type and age), the system shall control the battery charge voltage and continuously calculate: ● The true available backup time ● The remaining service life. 9.3 - Block by block monitoring To further optimise battery availability and service life, it shall be possible to equip the UPS with an optional system to continuously monitor all battery strings and display a block by block failure prediction. The system shall include the functions listed below. ● Continuous measurement of the voltage of each block. ● Continuous measurement of the internal resistance. ● Identification of faulty blocks (trend curves). ● Possibility of replacing individual blocks. ● Remoting of all information via Ethernet, dry contacts or JBus. 10 - User interface and communication 10.1 - User interface UPS operation shall be facilitated by a user interface, on each UPS unit, comprising: ● a graphic display; ● controls; ● status indications with mimic panel. The information and controls shall be centralised by a system (electronic board) built into one of the UPS units. 10.1.1 - Graphic display The graphic display shall facilitate operation by offering the functions listed below. ● operating language It shall be possible to display in the language all the operating information supplied on the screens. ● animated colour mimic diagram The mimic diagram shall enable display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass). ● step by step operating help The graphic display shall assist the user by providing step by step help in the user's language. ● display of measurements It shall be possible to display the following measurements: - inverter output phase-to-phase voltages; - inverter output currents; - inverter output frequency; - voltage across battery terminals; - battery charge or discharge current; - rectifier/charger input phase-to-phase voltages; - rectifier/charger input currents; - crest factor; - active and apparent power; - power factor of the load; - battery temperature. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.10 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) ● display of status conditions and events It shall be possible to display the following indications: - load on battery power; - load on UPS; - load on automatic bypass; - general alarm; - battery fault; - remaining battery backup time; - low battery warning; - bypass AC source outside tolerances; - battery temperature. Additional information shall be provided in view of accelerating servicing of the system, as specified in section 11 “Maintainability”. ● display of operating graphs It shall be possible to graphically display the measurements mentioned above on the screen over significant periods. ● log of time-stamped events This function shall store in memory and make available, for automatic or manually initiated recall, time-stamped logs of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. It shall be possible to time stamp and store at least 2 000 events. 10.1.2 - Controls The UPS shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of the UPS, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● EPO terminal block The UPS shall be equipped with an emergency power off terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of UPS units; - opening of the static switch on the bypass line and of the battery circuit breaker; - opening of an isolated dry contact on the programmable card. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. 10.1.3 - Status indications with mimic panel Indication of status conditions shall be distinct of the graphic display. Three LEDs on the control panel indicate the following status conditions: ● load protected; ● minor fault; ● major fault. The mimic panel shall represent the UPS and indicate the status of the load supply using five two-colour (red and green) LEDs: ● load supplied (LED at UPS output on mimic panel), ● inverter on (inverter LED on mimic panel), ● operation on battery power (LED between battery and inverter on mimic panel), ● bypass activated (bypass LED on mimic panel), ● PFC rectifier on (rectifier LED on mimic panel). APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.11 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 10.2 - Communication 10.2.1 - Standard communication It shall be possible to remote the following controls, indications and measurements. To that end, each UPS unit shall have as standard equipment: ● a programmable card for input/output information. This card shall provide a total of eight dry contacts, six for incoming information and two for outgoing information. ● at least three communication ports for later addition, without interrupting operation, of communication cards implementing different protocols, e.g. SNMP, JBus/ModBus, RS232, USB, XML. 10.2.2 - Communications options The UPS system shall be designed to enable the extension of communications, without system shutdown, to the following types of cards: ● an SNMP communication card for connection to an Ethernet network, for connection to a computer-network management system; ● an RS485 serial-link communication card capable of implementing the JBus/ModBus protocol for connection to a building management system (BMS); ● an RS232 serial-link communication card for communication with a modem and a remote-maintenance system; ● a USB communication card; ● an XML-Web communication card for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser. The UPS shall be detectable by supervision software for large UPS systems. Shutdown and administration software shall be available in addition to the communication cards. 11 - Maintainability 11.1 - Local and remote diagnostics and monitoring - E. Services ● The UPS shall be equipped with a self-test system to check operation of the system as a whole each time it is started. To that end, the supply control/monitoring electronics shall offer: ● auto-compensation of component drift; ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote); ● overall readiness for remote supervision services provided by the manufacturer. 12 - Standards, tests and quality assurance 12.1 - Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. ● IEC 6014B-4: UPS - Performance. ● IEC 62040-1 and EN 62040-1: UPS - Safety. ● IEC 62040-2 level A: UPS - Electromagnetic compatibility [level C3 / C2 class A is optional]. ● IEC 62040-3 and EN 62040-3: UPS - Performance. ● IEC 60950 / EN 60950: Safety of IT equipment, including electrical business equipment. ● IEC 61000-2-2: Compatibility levels for low-frequency conducted disturbances and signalling in public lowvoltage power supply systems. ● IEC 61000-3-4: Limits for harmonic current emissions (equipment input current > 16 A/ph). ● IEC 61000-4: EMC - Electrical fast transient/burst immunity. ● EN 55011 and EN 55022: Limits and methods of measurement of radio interference characteristics of industrial, scientific and medical (ISM) radio-frequency equipment - Level A conducted and radiated emissions. ● IEC 439: Low-voltage switchgear and controlgear assemblies. ● IEC 60529: Degrees of protection provided by enclosures (IP Code). ● ISO 3746: Sound power levels. ● CE marking. What is more, the equipment must comply with environmental-protection standards, with production taking place on premises certified ISO 14001. The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.12 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 12.2 - Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). 13 - Services 13.1 - Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 13.2 - Technical competency ● customer operators: the supplier shall offer a level 2 training program. ● service personnel: the supplier shall ensure that service personnel are qualified for level 4. 13.3 - Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorised agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). 13.4 - System start-up ● The system and equipment shall be started up on site by the supplier or its authorised agent. The procedure shall include checks on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. 13.5 - Replacement parts ● The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 13.6 - Recycling and renovation/substitution ● At the end of the UPS service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 14 - Warranty The rectifier/charger and inverter subassemblies shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.13 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) 15 - Services Required services include: ● supply of the UPS and any accessory parts or elements; ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site; ● connections between the battery and the UPS; ● connection of the normal AC source to the rectifier/charger; ● connection of the bypass AC source to the input transformer or bypass input; ● connection of the load circuits to the UPS output. 16 - Electrical diagram Fig. Simplified diagram of active redundancy with two identical integrated parallel UPS units. Fig. Simplified diagram for parallel connection, with or without active redundancy, of integrated parallel UPS units, with an external bypass cubicle (all UPS units must have identical ratings). The external bypass is sized to handle the total power of the three UPS units. APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.14 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) Appendix. Check list Type of UPS Total rated power (kVA) at PF 0.8 kVA Identical parallel-connected units units rated including redundant units units kVA each kVA and a manual maintenance bypass rated Manufacturer Range of products yes no yes no 342 - 470 V yes no at 0.90 Pn 250 - 470 V yes no at Pn 337-460 V or 352-480 V depending on connection yes no not requiring auxiliary cabinet yes no THDI upstream ≤ 3% yes no PF > 0.99 yes no constant from 30 to 100% of Pn yes no 45 - 65 Hz yes no yes no Operating mode (IEC 62040-2) double conversion Continuous operation at 40 °C Rectifiers Three-phase input voltage at Pn With auto-transformer option Sinusoidal current drawn (PFC) sinusoidal input current Input power factor THDI, PF performance Frequency No inrush or start-up current Rapid battery charger Backup time10 minutes in t ≤ 11 hours, 4 hours in t ≤ 24 hours yes no Voltage regulation ±1% yes no yes no yes no Independent regulation/monitoring systems Battery Type standard sealed lead acid in a cabinet Service life years yes no Backup time minutes yes no Battery management and protection Automatic entry of battery parameters yes Temperature correction yes Measurement of actual backup time, depending on: load, temperature, age yes yes Cold start on battery power Protection against deep discharge with circuit-breaker opening yes Charge-current limiting 0.05 C10 to 0.1 C10 (depending on the battery) yes APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.15 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) Self-tests yes no Battery meter yes no Block by block monitoring yes no yes no Inverters Volts Three-phase output voltage with neutral Compensation Adjustable line drop 0 to ± 5% yes no Steady-state conditions ± 1% yes no Voltage transients ± 3% (load from 0 to 100 or 100 to 0 %) yes no Output voltage distortion at Pn THDU ph-N < 2% for linear loads yes no THDU ph-N < 3% for non-linear loads yes no yes no Frequency synchronisation with an external Adjustable up to ± 8% of rated frequency source yes no Overload capacity 150% In for 1 minute yes no 210% In for 1 second yes no Current limiting 270% In for 150 milliseconds yes no Crest factor up to 3:1 yes no yes no yes no yes no Hz Output frequency With neutral Variation in output frequency ± 0.5 Hz Static bypass Static bypass Short-circuit withstand of static bypass 45 In at 20 kVA / 19 In at 120 kVA – 20 ms Maintenance bypass Efficiency Normal mode > 92% at Pn, > 90% at Pn/2 yes no ECO mode 97% at Pn yes no Centralised user interface on each UPS unit selection of operating language yes no Personalisation menu with password yes no Display measurements, status, events, graphs yes no Event log time-stamping yes no Controls ON, OFF, EPO terminal block yes no Status indications with mimic panel Audio alarm, LEDs yes no Graphic display in 15 languages APC by Schneider Electric 05/2009 edition Ch.6 spec. 6b – p.16 Specification guide no. 6b Parallel UPS, three-phase, 40 to 720 kVA (cont.) Communication Programmable relay card yes no EPO terminal block yes no 3 slots for communication cards yes no Options Ethernet SNMP card yes no RS485 JBus/Modbus card yes no RS232 U-Talk card yes no USB card yes no XML-Web card yes no Supervision software yes no with shutdown management yes no Certified standards and tests see list in section 12.1 yes no Certification of performance TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier Level 4 NFX 060-010 yes no Diagnostics and monitoring Remote yes no Technical support International yes no yes no Administration software Certification Services Operation, Maintainability Access to power components through front Access to communication through front hot-swap cards yes no Access to batteries through front hot-swap batteries yes no Around the world yes no Availability Availability of original replacement parts t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes yes no no Emergency services yes no Renovation / substitution programmes yes no Maintenance programmes APC by Schneider Electric Preventive Predictive 05/2009 edition Ch.6 spec. 6b – p.17 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA Contents 1 - UPS definition ............................................................................................................................... 2 1.1 - Purpose .............................................................................................................................. 2 1.2 - Brief description .................................................................................................................. 2 2 - Operating principle ...................................................................................................................... 2 2.1 - Normal operation ................................................................................................................ 2 2.2 - Operation on battery power ................................................................................................ 2 2.3 - Battery recharge ................................................................................................................. 2 2.4 - Static-bypass operation (static switch) ................................................................................ 2 2.5 - Operation of the manual maintenance bypass.................................................................... 3 2.6 - Operation without the battery .............................................................................................. 3 2.7 - Cold start (AC power absent) .............................................................................................. 3 3 - Sizing and general characteristics ............................................................................................. 3 3.1 - Technology ......................................................................................................................... 3 3.2 - Rating ................................................................................................................................. 3 3.3 - Battery backup time ............................................................................................................ 3 3.4 - Types of loads accepted ..................................................................................................... 3 3.5 - Limitation of harmonics upstream of the UPS ..................................................................... 3 3.6 - Efficiency ............................................................................................................................ 3 3.7 - Noise level .......................................................................................................................... 4 4 - AC sources ................................................................................................................................... 4 4.1 - Normal AC source .............................................................................................................. 4 4.2 - Bypass AC source .............................................................................................................. 4 5 - Electrical characteristics ............................................................................................................. 4 5.1 - Rectifier and charger........................................................................................................... 4 5.2 - Batteries.............................................................................................................................. 5 5.3 - Inverter................................................................................................................................ 5 5.4 - Static bypass ...................................................................................................................... 6 5.5 - Discrimination ..................................................................................................................... 7 5.6 - System earthing arrangement ............................................................................................. 7 6 - Mechanical characteristics .......................................................................................................... 7 6.1 - Scalable design .................................................................................................................. 7 6.2 - Dimensions ......................................................................................................................... 7 6.3 - Mechanical structure ........................................................................................................... 7 6.4 - Connections and busbars ................................................................................................... 8 6.5 - Ventilation ........................................................................................................................... 8 6.6 - Safety.................................................................................................................................. 8 7 - Environment conditions .............................................................................................................. 8 7.1 - UPS (not including battery) ................................................................................................. 8 7.2 - Batteries.............................................................................................................................. 8 8 - Protection ..................................................................................................................................... 9 8.1 - UPS .................................................................................................................................... 9 8.2 - Rectifier and charger........................................................................................................... 9 8.3 - Inverter................................................................................................................................ 9 8.4 - Batteries.............................................................................................................................. 9 9 - Battery management .................................................................................................................... 9 9.1 - Self-test............................................................................................................................... 9 9.2 - Temperature correction....................................................................................................... 9 9.3 - Measurement of actual backup time ................................................................................... 10 10 - User interface and communication........................................................................................... 10 11 - Maintainability ............................................................................................................................ 10 11.1 - Local and remote diagnostics and monitoring - E. Services ............................................. 10 12 - Standards and tests .................................................................................................................. 11 12.1 - Standards ......................................................................................................................... 11 12.2 - Certification of conformity ................................................................................................. 11 13 - Test procedures and quality system ........................................................................................ 11 14 - Services ...................................................................................................................................... 12 14.1 - Maintenance ..................................................................................................................... 12 14.2 - Technical competency ...................................................................................................... 12 14.3 - Functional components ..................................................................................................... 12 14.4 - System start-up ................................................................................................................. 12 14.5 - Replacement parts ............................................................................................................ 12 14.6 - Recycling and renovation.................................................................................................. 12 15 - Warranty...................................................................................................................................... 13 16 - Installation services ................................................................................................................... 14 17 - Electrical diagram ...................................................................................................................... 14 Appendix. Check list ......................................................................................................................... 15 APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 1 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 1 - UPS definition 1.1 - Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying and putting into operation an Uninterruptible Power Supply (referred to as a UPS in the rest of this document). The UPS shall be designed to supply dependable electric power to: 1.2 - Brief description The UPS shall be a single-UPS unit, operating in double-conversion mode (also called on-line mode), made up of the following components, described in detail in this specification: ● rectifier/charger; ● inverter; ● battery; ● static bypass (via a static switch); ● manual maintenance bypass. ● user and communications interface. ● battery management system. ● any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. The UPS shall ensure continuity of electric power to the load within the specified tolerances, without interruption upon failure or deterioration of the normal AC source (utility power) for a maximum protection time determined by the capacity of the backup batteries installed. 2 - Operating principle The UPS shall operate in double-conversion mode (VFI) as defined below. 2.1 - Normal operation (normal AC source available) The rectifier supplies the inverter with DC current while the charger simultaneously float charges the battery. The load is continuously supplied with dependable electrical power by the inverter. A current-loop system shall ensure automatic distribution of the total load between the various parallel-connected units. 2.2 - Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter shall continue to supply the load from battery power without interruption or disturbance, within the limits imposed by the specified battery backup time. 2.3 - Battery recharge (normal AC source restored) When the normal AC source is restored, the rectifier shall again power the inverter, without interruption or disturbance to the load, while the charger automatically recharges the battery. 2.4 - Static-bypass operation (static switch) In the event of an overload exceeding system capabilities (short-circuits, heavy inrush currents, etc.) or UPS shutdown (user-initiated for maintenance or automatic for internal faults), the static bypass switch shall instantaneously transfer the load to the bypass AC source without interruption, on the condition that bypass power is available and within tolerances. To that end, synchronization of the inverter in phase and frequency with the bypass source shall be automatic. Transfer of the load back to the UPS-unit output, synchronized with the bypass AC source, shall be automatic or manual. During transfer, the load shall not suffer an outage or disturbance in the supply of power. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 2 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 2.5 - Operation of the manual maintenance bypass The UPS shall include a manually-operated mechanical bypass system for maintenance purposes. For personnel safety during servicing or testing, this system shall be designed to isolate the rectifier, charger, inverter and static switch while continuing to supply power to the load from the bypass AC source. Transfer to the manual maintenance bypass and back shall be possible without interruption to the load. The UPS shall also include a device making it possible to isolate the rectifier and the charger from the normal AC source. 2.6 - Operation without the battery For safe maintenance on the battery, the system shall include a circuit breaker to isolate the battery from the rectifier, the charger and the inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.7 - Cold start (AC power absent) The battery shall be capable of ensuring UPS start-up even if normal AC power is not available and continuing operation within the specified back-up time. 3 - Sizing and general characteristics 3.1 - Technology The UPS shall be based on IGBT technology and a free-frequency chopping mode to ensure optimum efficiency and excellent voltage quality. 3.2 - Rating The UPS shall be sized to continuously supply a load of …[160 / 200]… kVA, at a power factor (pf) of 0.8. 3.3 - Battery backup time The battery backup time in the event of a normal AC source outage shall be …[ 8 / 10 / 15 / 30 / 60…]… minutes, for a load power factor of 0.8. Battery service life shall be equal to at least …[ 5 / 10 ]…years. It shall be selected and sized correspondingly, for a load power factor of 0.8. 3.4 - Types of loads accepted The UPS shall accept high crest factors (3:1) without derating. For both linear and non-linear loads, the total harmonic voltage distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU aval ph/ph ≤ 2 % ● THDU aval ph/N ≤ 3 %. 3.5 - Limitation of harmonics upstream of the UPS The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of guide IEC 61000-3-4 (formerly IEC 1000 3-4). To that end, it shall be possible to equip the rectifier/charger input with a filter of the type…[compensated LC / noncompensated LC / with contactor / double bridge / THM / phase shifting]… If necessary, it shall be possible to use an electronic active filtering system to obtain, at the normal AC input, the following levels, constant from 50% to 100% load: ● total harmonic current distortion (THDI) upstream of the rectifier not exceeding 4% at full rated load: THDI upstream ≤ 4% at Pn; ● input power factor (pf) greater than or equal to 0.94: FP ≥ 0.94. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 3 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 3.6 - Efficiency Overall efficiency shall be greater than or equal to: ● 93% down to half rated load (In/2). ● An optional economic operating mode (see section 5.4.2) shall be available to increase the efficiency up to a value of 97%. 3.7 - Noise level The noise level, measured as per standard ISO 3746, shall be less than: ● 68 dBA 4 - AC sources The UPS shall be designed to receive power from the sources listed below. 4.1 - Normal AC source (rectifier/charger input) The normal AC source supplying the UPS shall, under normal operating conditions, have the following characteristics: ● rated voltage: 380 - 400 or 415 volts rms at full rated load Pn; ● voltage: volts, ± 15%; ● number of phases: 3 + N + earth; ● frequency: Hz ± 10% 4.2 - Bypass AC source (static-bypass input, if separate from rectifier input) The bypass power supplying the UPS in the event of an inverter shutdown (maintenance, failure) or an overload (short-circuit, heavy inrush currents, etc.) shall have the following characteristics: ● voltage: / volts, ± 10%; ● number of phases: 3 + N + earth; (a non-distributed neutral is possible) ● frequency: Hz ± 5% 5 - Electrical characteristics 5.1 - Rectifier and charger 5.1.1 - Supply The rectifier and charger module shall be supplied via the normal AC input (see section 4 "AC sources"). 5.1.2 - Inrush current A walk-in circuit shall eliminate overcurrents during starting by imposing a gradual increase of the rectifier/charger input current until nominal conditions are reached. This walk-in period shall last approximately 10 seconds. 5.1.3 - Battery-current limiting For long battery life, an electronic device shall automatically limit the charging current to the maximum value specified by the battery supplier (0.1 x C10 for a sealed lead-acid battery). A second device shall limit the total current drawn by the rectifier/charger to avoid overloading the power supply line. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 4 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 5.1.4 - Operating modes and DC-voltage levels To substantially extend battery life without lowering its performance, the rectifier/charger shall provide four operating modes: ● Float-charging mode The battery-charger output voltage shall be set to the value specified by the battery supplier, i.e. volts/cell. ● Automatic charging mode In the event of a normal AC source outage lasting longer than a user-defined time, a battery charging cycle shall be automatically initiated upon restoration of the normal source. For fast recharging without lowering battery performance, this cycle shall include two charging phases, the first at constant current and the second at constant voltage. The constant voltage for the second phase shall be that specified by the battery supplier, i.e. volts/cell. Upon completion, the DC voltage shall return to the float charging value. ● Manual-charging mode The UPS shall also include a manually initiated 24-hour charge cycle. Upon completion, the DC voltage shall return to the float charging value. ● Initial or equalising charge mode For initial charging of a dry-fit battery or equalising of an installed battery showing a significant cell to cell voltage volts/cell. differential, the UPS shall allow charging at the voltage specified by the battery supplier, i.e. This operation shall be carried out with the inverter turned off. 5.1.5 - Input power factor The UPS shall present an input power factor greater than or equal to 0.98 for the normal AC source rated voltage and frequency and the inverter operating at full rated load. 5.1.6 - Voltage regulation Rectifier/charger regulation shall ensure DC output voltage fluctuations of less than 1% irrespective of load and AC input voltage variations (within the limits specified in section 4.1 “Normal AC source”). 5.2 - Batteries The battery shall be of the …[ sealed lead-acid type, factory mounted and wired in a cabinet identical to that of the UPS, ]…[sealed lead-acid type, mounted on shelves,]…[vented lead-acid type, mounted on a rack, ]... with a service life of …[ 5 / 10 ]… years. The battery shall be sized to ensure continuity in the supply of power to the inverter for at least …[ 8 / 10 / 15 / 30 / 60…]… minutes, in the event of a normal AC source failure, with the inverter operating at full rated load, i.e.…[160 / 200]… kVA at a power factor pf = 0.8. Sizing calculations shall assume an ambient temperature between 15° C and 25° C The UPS shall include devices to ensure: ● effective battery protection (see section 8.4 "Protection - Battery"); ● battery management (see section 9 "Battery management"). 5.3 - Inverter The inverter shall be sized to supply a rated load of …[160 / 200]… kVA at a power factor (pf) of 0.8 and shall satisfy the specifications listed below. 5.3.1 - Output voltage ● Rated voltage …[ 380 / 400 / 415 ]… volts rms, adjustable within a range of ± 3%. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions The variation in the rated voltage shall be limited to ± 1% for a balanced load between 0 and 100% of the rated power, irrespective of normal AC input and DC voltage levels, within the limits specified in section 4.1 “Normal AC source” and 5.1.4 “Rectifier/charger - Operating modes and DC-voltage levels”. ● Voltage transients (transient conditions) Output voltage transients shall not exceed ± 5% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 20 milliseconds. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 5 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) ● Unbalanced load conditions For a > 30% unbalanced load, the voltage unbalance shall be less than 2% for the phase-to-neutral amplitude and 3 degrees for the phase angle deviation. ● Phase-to-phase harmonic distortion (voltage wave form) The UPS shall limit distortion of the phase-to-phase output voltages to less than: - 1.5% for each harmonic; - 3% overall; irrespective of the type of load, as indicated in section 3.4 "Types of loads accepted". 5.3.2 - Output frequency ● Rated frequency Hz. ● Variations - ± 0.5 Hz, - adjustable from ± 0.25 Hz up to ± 2 Hz. 5.3.3 - Synchronization with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions below in section 5.4 "Static-bypass"), the inverter output voltage shall be synchronized with the bypass source voltage whenever possible. To that end, during normal operation, a synchronization system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within ± 1% of its rated value). ● Synchronization with an external source If the bypass source is a generator set, the synchronization tolerances shall be approximately ± 2 Hz (adjustable). ● Autonomous operation following loss of synchronization with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronization, regulating its own frequency to within ± 0.1%. When bypass power returns to within tolerances, the inverter shall automatically resynchronize. ● Variation in frequency per unit time During the switch to free-running mode and the switch back to synchronised mode, frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s or 2 Hz/s (user defined). 5.3.4 - Overload capacity The UPS shall be capable of supplying for at least: ● 10 minutes a load representing 125 % of the rated load; ● 1 minute a load representing 150% of the rated load. If necessary, the UPS shall operate as a generator (current limiting) with a peak capacity of 233% for 1 second, to allow highly disturbed transient operating states (high overloads, very high crest factors, etc.) without transferring the load to the bypass. 5.4 - Static bypass 5.4.1 - Static-bypass function Instantaneous transfer of the load from the inverter to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.2 "Bypass AC source" and that the inverter is synchronized. Transfer shall take place automatically in the event of a major overload or an internal inverter fault. Manually initiated transfer shall also be possible. If the bypass power is outside the specified tolerances or is not synchronized with the inverter, automatic transfer of the load from the inverter to bypass power shall take place after a calibrated interruption of 500 to 800 milliseconds. Manual initiation of this transfer as well as transfer back to the inverter shall also be possible. 5.4.2 - Option for optimized output - ECO mode The static switch associated with a microprocessor controlling the bypass shall provide an operating mode that increases the efficiency of the UPS up to 97% during periods when the bypass source is stable and within tolerances. It shall be possible for the operator to enable or disable this operating mode at any time. The time required to transfer the load to and from the bypass shall not exceed 15 milliseconds. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 6 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 5.5 - Discrimination If the bypass power is within the tolerances specified in section 4.1 "Bypass AC source" , the presence of the static switch shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the inverter. To ensure tripping in a selective manner, the available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated inverter current). If the bypass source is outside the specified tolerances, the inverter on its own shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of shortcircuit. 5.6 - System earthing arrangement The UPS shall be compatible with the following system earthing arrangements: ● upstream source: …[ TT/ IT / TNS / TNC ]… ● downstream installation: …[ TT/ IT / TNS / TNC ]… If the upstream and downstream earthing arrangements are different, galvanic isolation shall be provided. 6 - Mechanical characteristics 6.1 - Scalable design The UPS shall be of scalable design so as to allow the installed power to be easily increased on site by connection of additional UPS units, either to meet new load requirements or to enhance system reliability by introducing redundancy. It shall be possible to adapt a single UPS unit for connection with parallel UPS units directly on site, without returning the equipment to the factory and without causing excessive system downtime. Similarly, the UPS output frequency shall be readily adaptable on site from 50 to 60 Hz or vice-versa to meet possible changes in load requirements. 6.2 - Dimensions The UPS shall require as little floorspace as possible. To facilitate installation, UPS height shall not exceed 1 900 mm and passage through an 800 mm wide door shall be possible (with panels and/or doors removed, as necessary). To save considerable space, it shall be possible to install the UPS with its back right against a wall. 6.3 - Mechanical structure The mechanical structure of the UPS shall be sufficiently strong and rigid to withstand handling and installation operations without risk. Access to UPS subassemblies shall be through front doors. The sheet-metal elements in the structure shall be protected against corrosion by a suitable treatment, such as zinc electroplating, bichromating, epoxy paint or an equivalent. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 7 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 6.4 - Connections and busbars Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible at the bottom of the UPS or through the bottom for a false floor. Installation shall be facilitated by clear marking of connection terminals. Connections shall be made through the front of the UPS cabinets. All connections shall be directly accessible, without undoing any other connections. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 12 "Standards and tests". Any busbars shall be made of rectangular cross-section electrolytic copper or aluminium bars and mounted in compliance with the stipulations in section 6.6 "Safety". The cables shall comply with the standards listed in section 12 "Standards and tests" and be mounted in compliance with the stipulations in section 6.6 "Safety". The neutral conductor shall be oversized for any third-order harmonic currents and their multiples (the size of the neutral shall be 1.5 times that of each phase). 6.5 - Ventilation The UPS shall be provided with forced-air cooling. To avoid UPS shutdown in the event of a fan failure, redundant fans shall be provided on the UPS and fan failure shall initiate an alarm. 6.6 - Safety For the safety of maintenance personnel, the cabinet shall be provided with a manually operated mechanical bypass designed to isolate the rectifier/charger, inverter and static switch while continuing to supply the load from the bypass AC source. Control circuits shall be galvanically isolated from power circuits. Live parts that could be touched during normal operation or maintenance shall be protected by insulated barriers. Backfeed type protection shall be available as an option to mechanically disconnect the bypass source when operating on battery power or when bypass power is absent to avoid the backfeed of battery voltage into the bypass source. It shall also be possible to send to the UPS an external EPO order resulting in opening of the battery circuit breaker and the upstream circuit breaker. 7 - Environment conditions 7.1 - UPS (not including battery) 7.1.1 - Operation The UPS, not including the battery, shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: -5° C to +40° C. ● recommended temperature range: +15° C to + 25° C ; ● maximum average temperature: 35° C for 24 hours ● maximum temperature: 40° C for 8 hours; ● maximum relative humidity: 95% at 25° C; ● maximum altitude: 1000 meters. 7.1.1 - Operation The UPS, not including the battery, shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. 7.2 - Batteries 7.2.1 - Operation The battery shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: 0° C to +40° C. ● recommended temperature range: +15° C to + 25° C ; ● maximum relative humidity: 95%; ● maximum altitude: 1000 meters. 7.2.2 - Storage The battery shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 8 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 8 - Protection 8.1 - UPS The UPS shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2 - Rectifier and charger The rectifier/charger shall be equipped to receive an external order to automatically shut down under the following circumstances: ● emergency off; in this case, the shutdown will be accompanied by opening of the battery circuit breaker; ● battery room ventilation fault. The rectifier and the charger shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer. 8.3 - Inverter The load shall be protected against any overvoltages that could result from voltage regulation failure at the inverter output. The inverter (and the rectifier/charger module) shall automatically shut down if the DC voltage reaches the minimum value specified by the battery manufacturer. The inverter shall be equipped with an automatic shutdown system to protect its power circuits against overloads exceeding its overload capacity when bypass power is not available. In particular, a short-circuit on the load shall initiate a static shutdown of the inverter, without blowing a fuse. 8.4 - Batteries 8.4.1 - Protection against deep discharge and self-discharge The UPS shall comprise a battery-protection device against deep discharges, taking into account the discharge cycles, with a circuit breaker to isolate the battery. In particular, a safety device for the battery shall limit the discharge time to three times the backup time at full rated load to avoid excessive discharge at less than the rated output. A second device shall avoid self-discharge of the battery into the UPS control circuits during an extended shutdown of the UPS (over two hours). It shall be possible to disable this device as necessary. 8.4.2 - Self-test The battery-monitoring system shall include the following automatic features: ● check on the battery circuit every 12 hours; ● open-circuit battery test every month; ● partial-discharge test every three months. This self-test system shall, where necessary, initiate indications via LEDs on the front panel or a message to a remote monitoring system. 8.4.3 – Charge-current limiting The UPS shall comprise a device to limit the charge current for the battery (0.05 C10 to 0.1 C10). 9 - Battery management As the life of a battery is very sensitive to operating conditions, the battery shall be managed in an optimum manner. In addition to the devices indicated in "Protection - Battery" above, battery management features shall include the following: 9.1 - Self-test The battery shall include a self-test system initiated in two manners: ● as necessary by a manual command; ● automatically at user-defined intervals. This self-test system shall update the battery parameters and detect any abnormal deterioration to facilitate preventive maintenance. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 9 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 9.2 - Temperature correction The battery management system shall automatically adapt the battery voltage to the ambient temperature in order to optimize battery service life. 9.3 - Measurement of actual backup time The battery function shall be combined with a system that continuously monitors the actual backup time available (AC source present) or remaining (AC source absent), according to the actual load on the UPS, the battery temperature and the age of the battery. 10 - User interface and communication 10.1 - User interface 10.1.1 - Operating and start-up assistance The UPS shall be equipped with an operating and start-up assistance, a system providing start-up and operating assistance including: ● display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass); ● time-stamped logging and automatic or manually initiated recall of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. 10.1.2 - Controls The UPS shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of the UPS, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● keypad A keypad shall be provided to carry out the following operations: - forced transfer or forced shutdown of inverter when the bypass AC source is outside specified load tolerances; - equipment self-test and battery charge cycle. ● EPO terminal block The UPS shall be equipped with an emergency power off terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of the UPS; - opening of the static switch on the bypass line and of the battery circuit breaker; - opening of an isolated dry contact on the programmable card. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. ● self-test button ● battery charge-cycle control button 10.1.3 - Indications The following status information shall be monitored by indicating lights on the UPS front panel: ● rectifier/charger on; ● load on UPS; ● load on bypass; ● general alarm. A buzzer shall warn the user of faults, malfunctions or operation on battery power. This system shall be equipped with an alarm reset button (see section 10.1.2). 10.1.4 - Display of parameters A display unit shall indicate at least the following parameters in the language: ● remaining battery backup time; ● internal fan fault; ● low battery warning; ● position of switching devices; ● bypass AC source outside tolerances; ● battery temperature. Additional information shall be provided in view of accelerating servicing of the system, as specified in the “Maintenance” section. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 10 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 10.1.5 - Display of measurements The display unit shall also indicate the following measurements: ● ● ● ● ● ● ● ● ● ● inverter output phase-to-phase voltages; inverter output currents; inverter output frequency, voltage across battery terminals; battery charge or discharge current; rectifier/charger input phase-to-phase voltages; rectifier/charger input currents; crest factor; active and apparent power; power factor of the load. 10.2 - Communication 10.2.1 - Standard communication ● a remote control and indication unit, for which the UPS shall be provided as standard with dry contacts for incoming and outgoing signals; 10.2.2 - Communications options The UPS shall be designed to enable the extension of communications, without system shutdown, to the following types of cards: ● an SNMP communication card for connection to an Ethernet network, for connection to a computer-network management system; ● an RS485 serial-link communication card capable of implementing the JBus/ModBus protocol for connection to a building management system (BMS); ● an RS232 serial-link communication card for communication with a modem and a remote-maintenance system; ● USB communication card; ● an XML-Web (HTTP) communication card for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser. In addition, it shall be possible to extend communication to other UPS units for simultaneous shutdown of a number of servers. Shutdown and administration software shall be available in addition to the communication cards. 11. - Maintainability ● All power subassemblies shall be accessible from the front. ● UPS design shall provide maximum mean time between failure (MTBF) and minimum mean time to repair (MTTR). 11.1 - Local and remote diagnostics and monitoring - E. Services The UPS shall be equipped with a self-test system to check operation of the system as a whole. The electronic UPS control and monitoring assembly shall therefore be fully micro-processor based, thus doing away with all potentiometer settings and making possible: ● auto-compensation of component drift; ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote). System components shall be ready for customer type (level 2) or manufacturer type (level 4) electronic mediation of services and/or monitoring. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 11 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 12 - Standards and tests 12.1 - Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. ● IEC 60146-4: UPS - Performance. ● IEC 62040-1 and EN 62040-1: UPS - Safety. ● IEC 62040-2 and EN 62040-2: UPS - Electromagnetic compatibility. ● IEC 62040-3 and EN 62040-3: UPS - Performance. ● IEC 60950 / EN 60950: Safety of IT equipment, including electrical business equipment. ● IEC 61000-2-2: Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. ● IEC 61000-3-4: Limits for harmonic current emissions (equipment input current > 16 A/ph). ● IEC 61000-4: EMC - Electrical fast transient/burst immunity. ● EN 55011 and EN 55022: Limits and methods of measurement of radio interference characteristics of industrial, scientific and medical (ISM) radio-frequency equipment - Level B conducted and radiated emissions. ● IEC 439: Low-voltage switchgear and controlgear assemblies. ● IEC 60529: Degrees of protection provided by enclosures (IP Code). ● ISO 3746: Sound power levels. ● CE marking. What is more, the equipment must comply with environmental-protection standards, with production taking place on premises certified ISO 14001. 12.2 - Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). 13 - Test procedures and quality system 13.1 - Test procedures The UPS manufacturer shall provide proof of a stringent Quality Assurance programme. In particular, the main equipment manufacturing stages shall be sanctioned by appropriate tests such as: ● incoming components inspection, discrete subassembly testing; ● complete functional checks on the final product. Equipment shall undergo on-load burn-in before leaving the factory. Final inspection and adjustments shall be documented in a report drawn up by the supplier’s Quality Inspection department. ISO 9001 or 9002 certification of the production site is compulsory. 13.2 - Quality system The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 12 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 14 - Services 14.1 - Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 14.2 - Technical competency ● Customer operators: the supplier shall offer a level 2 training program. ● Service personnel: the supplier shall ensure that service personnel are qualified for level 4. 14.3 - Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorized agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). 14.4 - System start-up ● The system and equipment shall be started up on site by the supplier or its authorized agent. The procedure shall include checks on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. 14.5 - Replacement parts ● The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 14.6 - Recycling and renovation/substitution ● At the end of the UPS service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 15 - Warranty The rectifier/charger and inverter subassemblies shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 13 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) 16 - Installation services Required services include: ● supply of the UPS and any accessory parts or elements; ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site; ● connections between the battery and the UPS; ● connection of the normal AC source to the rectifier/charger; ● connection of the bypass AC source to the input transformer or bypass input; ● connection of the load circuits to the UPS output. 17 - Electrical diagram Fig. UPS electrical diagram. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 14 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) Appendix. Check list Type of UPS Total rated power (kVA) at PF 0.8 kVA Manufacturer Range of products double conversion yes no Three-phase input voltage at Pn 380 or 440 or 415 V ± 15% yes no Input frequency 50 or 60 Hz ± 10% yes no Input-current distortion THDI upstream ≤ 4% with THM filter yes no Input power factor PF > 0.94 yes no sealed lead acid in a cabinet yes no yes no Operating mode (IEC 62040-2) Rectifiers Battery Type standard other Service life years yes no Backup time minutes yes no yes no yes no yes no yes no yes no yes no yes no Battery management and protection Temperature correction Measurement of actual backup time, depending on: load, temperature, age Cold start on battery power Protection against deep discharge with circuit-breaker opening Protection against self-discharge Charge-current limiting 0.05 C10 to 0.1 C10 (depending on the battery) Self-tests APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3a - p. 15 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) Inverter Volts yes no ± 3% yes no Steady-state conditions ± 1% yes no Voltage transients ± 5 % (load from 0 to 100 or 100 to 0 %) yes no Output voltage distortion at Pn THDU ph-N < 3% yes no Hz yes no ± 0.5 Hz yes no ± 0.25 Hz to 2 Hz yes no Frequency synchronization with an external source ± 8 % of rated frequency source yes no Overload capacity 125 % In for 10 minutes yes no 150 % In for 1 minute yes no Current limiting 233 % In for 1 second yes no Crest factor up to 3:1 yes no yes no yes no yes no > 93% at Pn/2 yes no Display measurements, status, events yes no Controls ON, OFF, EPO terminal block yes no Status indications Audio alarm, LEDs yes no Programmable relay card yes no EPO terminal block yes no 3 slots for communication cards yes no Options Ethernet SNMP card yes no RS485 JBus/Modbus card yes no RS232 U-Talk card yes no USB card yes no XML-Web card yes no Supervision software yes no yes no Three-phase output voltage with neutral adjustable to Output frequency Variation in output frequency adjustable from Static bypass Standard function Short-circuit withstand of static bypass 10 In – 20 milliseconds Maintenance bypass Efficiency Normal mode User interface Communication Administration software APC by Schneider Electric with shutdown management 05/2009 edition ch. 6 – spec. 3a - p. 16 Standard specification no. 3a Single UPS, three-phase, 160 to 200 kVA (cont.) Certification Certified standards and tests see list in section 12.1 yes no Certification of performance TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier Level 4 NFX 060-010 yes no Diagnostics and monitoring Remote yes no Technical support International yes no Access to power components through yes no Back-to-wall installation for units > 160 yes no yes no Services Operation, Maintainability Availability Availability of original replacement parts Around the world t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes yes no no Emergency services yes no Renovation / substituion programmes yes no Maintenance programmes APC by Schneider Electric Preventive Predictive 05/2009 edition ch. 6 – spec. 3a - p. 17 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA* * Maximum power rating without redundancy Contents 1 - UPS definition ............................................................................................................................... 2 1.1 - Purpose .............................................................................................................................. 2 1.2 - Brief description .................................................................................................................. 2 2 - Operating principle ...................................................................................................................... 2 2.1 - Normal operation ................................................................................................................ 2 2.2 - Operation on battery power ................................................................................................ 2 2.3 - Battery recharge ................................................................................................................. 3 2.4 - Redundancy ........................................................................................................................ 3 2.5 - Transfer to bypass AC source ............................................................................................ 3 2.6 - Maintenance on UPS units ................................................................................................. 3 2.7 - Battery maintenance ........................................................................................................... 3 2.7 - Cold start (AC power absent) .............................................................................................. 3 3 - Sizing and general characteristics ............................................................................................. 3 3.1 - Technology ......................................................................................................................... 3 3.2 - Rating ................................................................................................................................. 4 3.3 - Battery backup time ............................................................................................................ 4 3.4 - Reliability and MTBF ........................................................................................................... 4 3.5 - Types of loads accepted ..................................................................................................... 4 3.6 - Limitation of harmonics upstream of the UPS ..................................................................... 4 3.7 - Efficiency ............................................................................................................................ 4 3.8 - Noise level .......................................................................................................................... 4 4 - AC sources ................................................................................................................................... 5 4.1 - Normal AC source .............................................................................................................. 5 4.2 - Bypass AC source .............................................................................................................. 5 5 - Electrical characteristics ............................................................................................................. 5 5.1 - Rectifier/chargers ................................................................................................................ 5 5.2 - Batteries.............................................................................................................................. 6 5.3 - Inverters .............................................................................................................................. 6 5.4 - Static-bypass ...................................................................................................................... 7 5.5 - Discrimination ..................................................................................................................... 7 5.6 - System earthing arrangement ............................................................................................. 7 6 - Mechanical characteristics .......................................................................................................... 8 6.1 - Scalable design .................................................................................................................. 8 6.2 - Dimensions ......................................................................................................................... 8 6.3 - Mechanical structure ........................................................................................................... 8 6.4 - Connections and busbars ................................................................................................... 8 6.5 - Safety.................................................................................................................................. 8 7 - Environment conditions .............................................................................................................. 9 7.1 - UPS (not including battery) ................................................................................................. 9 7.2 - Batteries.............................................................................................................................. 9 8 - Protection ..................................................................................................................................... 9 8.1 - UPS .................................................................................................................................... 9 8.2 - Rectifier/chargers ................................................................................................................ 9 8.3 - Inverters .............................................................................................................................. 9 8.4 - Batteries.............................................................................................................................. 10 9 - Battery management .................................................................................................................... 10 9.1 - Automatic entry of parameters ............................................................................................ 10 9.2 - Temperature correction....................................................................................................... 10 9.3 - Measurement of actual backup time ................................................................................... 10 10 - User interface and communication........................................................................................... 10 10.1 - User interface ................................................................................................................... 10 10.2 - Communication ................................................................................................................. 11 11 - Maintenance................................................................................................................................ 12 12 - Standards and tests .................................................................................................................. 12 13 - Test procedures and quality system ........................................................................................ 13 14 - Services ...................................................................................................................................... 13 14.1 - Maintenance ..................................................................................................................... 13 14.2 - Technical competency ...................................................................................................... 13 14.3 - Functional components ..................................................................................................... 13 14.4 - System start-up ................................................................................................................. 13 14.5 - Replacement parts ............................................................................................................ 14 14.6 - Recycling and renovation.................................................................................................. 14 15 - Warranty...................................................................................................................................... 14 16 - Installation services ................................................................................................................... 14 17 - Electrical diagram ...................................................................................................................... 15 Appendix. Check list ......................................................................................................................... 16 APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 1 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 1 - UPS definition 1.1 - Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying, putting into operation and maintaining an Uninterruptible Power Supply system (referred to as a UPS in the rest of this document). The UPS system shall be designed to supply dependable electric power to: For information purposes MTBF in hours 475000 Single-UPS unit with static bypass Non availability 2.1x10 -5 Active redundancy N+1 with 1.88x106 1.25x106 9.39x105 -2 UPS units -3 UPS units -4 UPS units The total load supplied by the UPS system shall be equal to pf = 0.8. 5.32x10-6 7.98x10-6 1.07x10-5 kVA, at a power factor 1.2 - Brief description The UPS system shall be made up of …[ 2 / 3 / 4 ]… identical parallel-connected single-UPS units (same power rating), operating in double-conversion mode (also called on-line mode). Each UPS unit shall have a unit rating of …[ 160 / 200 ]… kVA and shall comprise the following components, described below in this specification: ● rectifier/charger; ● Inverter; ● Battery; ● Static bypass (via a static switch) for each UPS unit; ● anual maintenance bypass for each UPS unit ( only for systems with two redundant UPS units) or a "maintenance bypass" cabinet ( for other systems) ● User and communications interface; ● Battery management system; ● Any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. The UPS system shall ensure continuity of electric power to the load within the specified tolerances, without interruption upon failure or deterioration of the normal AC source (utility power) for a maximum protection time determined by the capacity of the backup batteries installed. 2 - Operating principle Each double-conversion UPS unit shall operate as defined below. 2.1 - Normal operation (normal AC source available) The rectifier/charger supplies the corresponding inverter with DC current while simultaneously float charging its battery. The load is continuously supplied with dependable electrical power by the inverter. A current-loop system shall ensure automatic distribution of the total load between the various parallel-connected units. 2.2 - Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter shall continue to supply the load with power from its battery without interruption or disturbance, within the limits imposed by the specified battery backup time. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 2 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 2.3 - Battery recharge (normal AC source restored) When the normal AC source is restored, the rectifier/charger shall again power the corresponding inverter, without interruption or disturbance to the load, while automatically recharging its battery. 2.4 - Redundancy The units shall operate in parallel and redundantly, with the load shared equally between the units. Redundancy shall be of the "n+1" (or n+2) type, i.e. "1" (or 2) units shall be redundant in the total of n units. If a major fault occurs on a unit, it shall automatically disconnect. If the remaining unit(s) are sufficient to supply the load, it/they shall remain in operation. If the total available power is insufficient, the load shall be automatically transferred, without interruption, to the bypass AC source, if it is within tolerances. 2.5 - Transfer to bypass AC source In the event of an overload exceeding system capabilities (short-circuits, heavy inrush currents, etc.) the load shall be automatically transferred, instantaneously and without interruption, to the bypass AC source, on the condition that bypass power is available and within tolerances. To that end, synchronization of each inverter in phase and frequency with the bypass source shall be automatic. Transfer of the load back to the UPS-unit outputs shall be automatic or manual. During transfer, the load shall not suffer an outage or disturbance in the supply of power. On request, the UPS system may automatically transfer the load with a micro-interruption if a major fault occurs on the UPS system and if synchronization with the bypass source has not been established. 2.6 - Maintenance on UPS units For maintenance purposes, a built-in manually-operated mechanical bypass system shall be: - installed in each UPS unit; ( only for a system with two redundant UPS units) - installed separately in a "maintenance bypass" cabinet. ( for other systems) For personnel safety during servicing or testing, this system shall be designed to isolate the UPS units while continuing to supply power to the load from the bypass AC source. Transfer to the manual bypass mode and back shall be possible without interruption to the load. The UPS shall also include a device making it possible to isolate the rectifier/chargers from the normal AC source. ( for a "maintenance bypass" cabinet). Remote information on the status of the external manual-bypass switch on the UPS units shall be available to avoid any risk of parallel connection of the normal and bypass AC inputs. 2.7 - Battery maintenance For safe maintenance on the battery of each UPS unit, the system shall include a circuit breaker to isolate the battery from the corresponding rectifier/charger and inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.8 - Coldstart (AC power absent) The battery of each UPS unit shall be capable of ensuring UPS start-up even if normal AC power is not available and continuing operation within the specified back-up time. 3 - Sizing and general characteristics 3.1 - Technology The UPS shall be based on IGBT technology and a free-frequency chopping mode to ensure optimum efficiency and excellent voltage quality. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 3 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 3.2 - Rating The UPS system shall be sized to continuously supply a load of kVA, at a power factor (pf) of 0.8. It shall be made up of ...[2 / 3 / 4 ]... UPS units, each with an identical rating of…[ 160 / 200 / ]… kVA. The total installed power rating shall thus be kVA. ...[Consequently, 1 (or 2) unit(s) may be redundant.] 3.3 - Battery backup time The backup time of each battery in the event of a normal AC source outage shall be …[ 8 / 10 / 15 / 30 / 60…]…minutes. The service life of each battery shall be equal to at least …[5 / 10]… years. Batteries shall be selected and sized accordingly. 3.4 - Reliability and MTBF 6 6 5 The active redundancy architecture shall provide an installation MTBF of …[1.88x10 / 1.25x10 / 9.39x10 hours ] corresponding to an availability of [5.32x10-6 / 7.98x10-6 / 1.07x10-5 ] 3.5 - Types of loads accepted If all the connected loads are non-linear (100% non-linear loads), each UPS unit shall accept high crest factors (3:1) without derating of output, for enhanced support of computer loads. For both linear and non-linear loads, the voltage total harmonic distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU downstream ph/N ≤ 2.5%; ● THDU downstream ph/ph ≤ 3%. 3.6 - Limitation of harmonics upstream of the UPS The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of standard IEC 61000-3-4 (formerly IEC 1000 3-4). To that end, it shall be possible to equip each rectifier/charger input with a filter of the type …[compensated LC / non-compensated LC / with contactor / double-bridge / phase shifting]... If necessary, it shall be possible to use an electronic active filtering system to obtain, at the normal AC input, the following levels, constant from 50% to 100% load: ● Total harmonic current distortion (THDI) upstream of the rectifier/charger not exceeding 4%; ● Input power factor (pf) greater than 0.94. 3.7 - Efficiency Overall efficiency of each UPS unit shall be greater than or equal to: ● 92% at full rated load (In); ● 91% a half rated load (In/2); 3.8 - Noise level The noise level, measured as per standard ISO 3746, shall for each unit be less than: ● 68 dBA. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 4 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 4 - AC sources The UPS system shall be designed to receive power from the sources presented below. 4.1 - Normal AC source (rectifier/charger inputs) The normal AC source supplying the UPS shall, under normal operating conditions, have the following characteristics: ● Rated voltage: 380 - 400 or 415 volts rms at full rated load Pn; volts, ± 15%; ● Voltage: ● Number of phases: 3 + N + earth; ● Frequency: Hz ± 10% 4.2 - Bypass AC source (static-bypass inputs, if separate from rectifier input) The bypass power supplying the UPS in the event of an inverter shutdown (maintenance, failure) or an overload (short-circuit, heavy inrush currents, etc.) shall have the following characteristics: volts, ± 10%; ● Voltage: / ● Number of phases: 3 + N + earth; ● Frequency: Hz ± 5% 5 - Electrical characteristics 5.1 - Rectifier/chargers 5.1.1 - Supply Each rectifier/charger shall be supplied via the normal AC input (see section 4, "AC sources") and shall have the characteristics presented below. 5.1.2 - Inrush current A walk-in circuit shall eliminate overcurrents during starting by imposing a gradual increase of the rectifier/charger input current until nominal conditions are reached. This walk-in period shall last approximately 10 seconds. 5.1.3 - Battery-current limiting For long battery life, an electronic device shall automatically limit the charging current to the maximum value specified by the battery supplier (0.1 x C10 for a sealed lead-acid battery). A second device shall limit the total current drawn by the rectifier/charger to avoid overloading the power supply line. 5.1.4 - Operating modes and DC-voltage levels To substantially extend battery life without lowering its performance, the rectifier/charger shall provide four operating modes: ● Float-charging mode The battery-charger output voltage shall be set to the value specified by the battery supplier, i.e. volts/cell. ● Automatic charging mode In the event of a normal AC source outage lasting longer than a user-defined time, a battery charging cycle shall be automatically initiated upon restoration of the normal source. For fast recharging without lowering battery performance, this cycle shall include two charging phases, the first at constant current and the second at constant voltage. The constant voltage for the second phase shall be that specified by the battery supplier, i.e. volts/cell. Upon completion, the DC voltage shall return to the float charging value. ● anual-charging mode The UPS shall also include a manually initiated 24-hour charge cycle. Upon completion, the DC voltage shall return to the float charging value. ● Initial or equalising charge mode For initial charging of a dry-fit battery or equalising of an installed battery showing a significant cell to cell voltage differential, the UPS shall allow charging at the voltage specified by the battery supplier, i.e. volts/cell. This operation shall be carried out with the inverter turned off. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 5 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 5.1.5 - Input power factor The rectifier/charger shall present an input power factor greater than or equal to 0.8 for the normal AC source rated voltage and frequency and the inverter operating at full rated load. 5.1.6 - Voltage regulation Rectifier/charger regulation shall ensure DC output voltage fluctuations of less than 0.5% irrespective of load and AC input voltage variations (within the limits specified in the “Normal AC source” section). 5.2 - Batteries Each UPS unit shall be equipped with its own battery of the …[sealed lead-acid type, factory mounted and wired in a cabinet identical to that of the UPS,] … [sealed lead-acid type, mounted on shelves,]…[vented lead-acid type, mounted on a rack,]... with a service life equal to at least …[5 / 10]… years. Each battery shall be sized to ensure continuity in the supply of power to the corresponding inverter for at least …[8 / 10 / 15 / 30 / 60…]… minutes, in the event of a normal AC source failure, with the inverter operating at full rated load, i.e. kVA at a power factor (pf) of 0.8. Sizing calculations shall assume an ambient temperature between 15° C and 25° C. Protection devices shall be incorporated in each cabinet. The battery shall be protected against deep discharge. 5.3 - Inverters Each inverter shall be sized to supply a load rated of …[ 160 / 200 ]… kVA at a power factor (pf) of 0.8, taking into account the characteristics presented below. 5.3.1 - Output voltage ● Rated voltage …[ 380 / 400 / 415 ]… volts rms, adjustable within a range of ± 3%. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions The variation in the rated voltage shall be limited to ± 1% for a balanced load between 0 and 100% of the rated power, irrespective of normal AC input and DC voltage levels, within the limits specified in section 4.1 “Normal AC source” and 5.1.4 “Rectifier/charger - Operating modes and DC-voltage levels”. ● Voltage transients (transient conditions) Output voltage transients shall not exceed ± 5% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 20 milliseconds. ● Unbalanced load conditions For a load unbalance greater than 30%, the voltage unbalance shall be less than 2% for the phase-to-neutral amplitude and 3 degrees for the phase angle deviation. ● Phase-to-phase harmonic distortion (voltage wave form) The UPS system shall be provided with a system limiting total harmonic distortion of the phase-to-phase output voltage to 3% and individual harmonic distortion to 1.5%, irrespective of the type of load, as indicated in section 3.5 "Types of loads accepted". 5.3.2 - Output frequency ● Rated frequency - Hz. ● Variations - ± 0.5 Hz, - adjustable from ± 0.25 Hz up to ± 2 Hz. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 6 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 5.3.3 - Synchronization with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions below in section 5.4 "Static-bypass"), the inverter output voltage shall be synchronized with the bypass source voltage whenever possible. To that end, during normal operation, a synchronization system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within ± 0.5 Hz of its rated value). ● Synchronization with an external source If the bypass source is a generator set, the synchronization tolerances shall be approximately ± 2 Hz (adjustable). ● Autonomous operation following loss of synchronization with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronization, regulating its own frequency to within ± 0.04%. When bypass power returns to within tolerances, the inverter shall automatically resynchronize. ● Variation in frequency per unit time During the switch to free-running mode and the switch back to synchronised mode, frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s. 5.3.4 - Overload capacity Each inverter in the UPS system shall be capable of supplying for at least: ● 10 minutes a load representing 125% of the rated load; ● 1 minute a load representing 150% of the rated load. If the bypass AC source is outside tolerances, the UPS shall operate as a generator (current limiting) with a peak capacity of 233% for 1 second, to allow highly disturbed transient operating states (high overloads, very high crest factors, etc.). 5.4 - Static-bypass Each UPS unit shall be equipped with a static bypass. The static bypasses shall be controlled simultaneously by a built-in system. Instantaneous transfer of the load from the inverters to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.1 "Bypass AC source" and that the inverters are synchronized. 5.5 - Discrimination and short-circuit capacity If the bypass power is within the tolerances specified in section 4.1 "Bypass AC source" , the presence of the static switch shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the common inverter output. To ensure tripping in a selective manner, the available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated UPS-system current). If the bypass source is outside the specified tolerances, the UPS system on its own shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of short-circuit. Parallel connection of a number of UPS units shall significantly improve discrimination. 5.6 - System earthing arrangement The UPS shall be compatible with the following system earthing arrangements: ● upstream source: …[ TT/ IT / TNS / TNC ]… ● downstream installation: …[ TT/ IT / TNS / TNC ]… If the upstream and downstream earthing arrangements are different, galvanic isolation shall be provided on the static-bypass line. (Except when the switch is from TNC to TNS, in which case the galvanic isolation is not required.) APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 7 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 6 - Mechanical characteristics 6.1 - Scalable design The UPS system shall be designed to allow the installed power to be easily increased on site by connection of additional UPS units, either to meet new load requirements or to enhance system reliability by introducing redundancy. This transformation shall be possible directly on site, without returning the equipment to the factory and without causing excessive system downtime. Similarly, the UPS output frequency shall be readily adaptable on site from 50 to 60 Hz or vice-versa to meet possible changes in load requirements. 6.2 - Dimensions Each UPS unit shall require as little floor space as possible. To facilitate installation, UPS height shall not exceed 1 900 mm and passage through an 800 mm wide door shall be possible (with panels and/or doors removed, as necessary). To save considerable space, it shall be possible to install the UPS units back to a wall. 6.3 - Mechanical structure The mechanical structure of each UPS unit shall be sufficiently strong and rigid to withstand handling and installation operations without risk. Access to UPS subassemblies shall be through front doors equipped with locking facilities. Rear panels shall be removable. The sheet-metal elements in the structure shall be protected against corrosion by a suitable treatment, such as zinc electroplating, bichromating, epoxy paint or an equivalent. 6.4 - Connections and busbars Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible at the bottom of the UPS or through the bottom for a false floor. Installation shall be facilitated by clear marking of connection terminals. Connections shall be made through the front of the UPS cabinets. All connections shall be directly accessible, without undoing any other connections. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 12 "Standards and tests". Any busbars shall be made of rectangular cross-section electrolytic copper or aluminium bars and mounted in compliance with the stipulations in section 6.6 "Safety". The cables shall comply with the standards listed in section 12 "Standards and tests" and be mounted in compliance with the stipulations in section 6.6 "Safety". The neutral conductor shall be oversized for any third-order harmonic currents and their multiples (the size of the neutral shall be 1.5 times that of each phase). 6.5 - Safety The equipment shall meet the requirements of degree of protection index IP21, in compliance with standard IEC 60529. For the safety of maintenance personnel, the cabinet shall be provided with a manually operated mechanical bypass designed to isolate the rectifier, charger, inverter and static switch while continuing to supply the load from the bypass AC source. Control circuits shall be galvanically isolated from power circuits. Live parts that could be touched during normal operation or maintenance shall be protected by insulated barriers. It shall be possible to send to the UPS an external EPO order resulting in opening of the battery circuit breaker and the upstream circuit breaker. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 8 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 7 - Environment conditions 7.1 - UPS (not including battery) 7.1.1 - Operation The UPS, not including the battery, shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: -5° C to +40° C. ● maximum temperature: 40° C for 8 hours; ● maximum relative humidity: 95% at 25° C; ● maximum altitude: 1000 meters. 7.1.2 - Storage The UPS, not including the battery, shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. 7.2 - Batteries 7.2.1 - Operation The battery shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: 0° C to +40° C. ● recommended temperature range: +15° C to + 25° C; ● maximum relative humidity: 95%; ● maximum altitude: 1000 meters. 7.2.2 - Storage The battery shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. 8 - Protection 8.1 - UPS Each UPS unit shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2 - Rectifier and charger Each rectifier/charger shall be equipped to receive an external order to automatically shut down under the following circumstances: ● emergency off; in this case, the shutdown will be accompanied by opening of the battery circuit breaker; ● battery room ventilation fault. The rectifier and the charger shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer. 8.3 - Inverter The load shall be protected against any overvoltages that could result from voltage regulation failure at the output of the inverters. The inverter (and the corresponding rectifier/charger) shall automatically shut down if the DC voltage reaches the minimum value specified by the battery manufacturer. Each inverter shall be equipped with an automatic shutdown system to protect its power circuits against overloads exceeding UPS-system overload capacity when bypass power is not available. In particular, a short-circuit on the load shall initiate a static shutdown of each inverter, without blowing a fuse. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 9 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 8.4 - Batteries 8.4.1 - Protection against deep discharge and self-discharge The UPS shall comprise a device designed to protect the battery against deep discharges, taking into account the characteristics of the discharge cycles, with isolation of the battery by a circuit breaker. In particular, a safety device on each battery shall limit the discharge time to three times the backup time at full rated load to avoid excessive discharge at less than the rated output. A second device shall avoid self-discharge of the battery into the UPS control circuits during an extended shutdown of the UPS (over two hours). It shall be possible to disable this device as necessary. 8.4.2 - Self-test The battery-monitoring system shall include automatic test devices for the battery in each unit for: ● check on the battery circuit every 12 hours; ● open-circuit battery test every month; ● partial-discharge test every three months. This self-test system shall, where necessary, initiate indications via LEDs on the front panel or a message to a remote monitoring system. 8.4.3 - Charge-current limiting The UPS shall comprise a device to limit the charge current for each battery (0.05 C10 to 0.1 C10). 9 - Battery management As the life of the batteries is very sensitive to operating conditions, the battery shall be managed in an optimum manner. In addition to the devices indicated in section 8.4 "Batteries", the battery-management system shall include the features listed below. 9.1 - Self-test The battery-monitoring system shall include an automatic test device for partial discharge. It shall be possible to adjust the frequency of the test. This self-test system shall, where necessary, initiate indications via LEDs on the front panel or a message to a remote monitoring system. 9.2 - Temperature correction The battery management system shall automatically adapt the battery voltage to the ambient temperature in order to optimize battery service life. 9.3 - Measurement of actual backup time The battery function shall be combined with a system that continuously monitors the actual backup time available (AC source present) or remaining (AC source absent), according to the actual load on the UPS, the battery temperature and the age of the battery. 10 - User interface and communication 10.1 - User interface 10.1.1 - Operating and start-up assistance Each UPS unit shall be equipped with a system providing start-up and operating assistance including: ● display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass); ● time-stamped logging and automatic or manually initiated recall of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 10 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 10.1.2 - Controls Each UPS unit shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of each UPS unit, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● keypad A keypad shall be provided to carry out the following operations: - forced transfer or forced shutdown of inverter when the bypass AC source is outside specified load tolerances; - equipment self-test and battery charge cycle. ● EPO terminal block The UPS shall be equipped with an emergency power off terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of each UPS unit; - it shall also be possible simultaneously to open the static switch of each UPS unit and the circuit breaker of each battery. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. ● battery charge-cycle control button on each UPS unit. 10.1.3 - Indications The following status information shall be monitored by indicating lights on the front panel of each UPS unit: ● rectifier/charger on; ● load on UPS; ● load on bypass; ● general alarm. A buzzer shall warn the user of faults, malfunctions or operation on battery power. This system shall be equipped with an alarm reset button (see section 10.1.2). 10.1.4 - Display of parameters A display unit on each UPS unit shall indicate at least the following parameters in the language: ● remaining battery backup time; ● internal faults; ● low battery warning; ● position of switching devices; ● bypass AC source outside tolerances; ● battery temperature. Additional information shall be provided in view of accelerating servicing of the system, as specified in the “Maintainability” section. 10.1.5 - Display of measurements The display unit shall also indicate the following measurements: ● inverter output phase-to-phase voltages; ● inverter output currents; ● inverter output frequency, ● voltage across battery terminals; ● battery charge or discharge current; ● rectifier/charger input phase-to-phase voltages; ● rectifier/charger input currents; ● crest factor; ● active and apparent power; ● power factor of the load. 10.2 - Communication 10.2.1 - Standard communication It shall be possible to remote the following controls, indications and measurements to: ● a remote control and indication unit, for which the UPS shall be provided as standard with dry contacts for incoming and outgoing signals; ● a microcomputer equipped with interface software, for use in a supervision system, for which the UPS shall be provided on option with a serial-link communication card; ● a remote maintenance and service center, for which an optional modem shall be available for the UPS. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 11 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 10.2.2 - Communications options The UPS shall be designed to enable the extension of communications, without system shutdown, to the following types of cards: ● an SNMP communication card for connection to an Ethernet network, for connection to a computer-network management system; ● an RS485 serial-link communication card capable of implementing the JBus/ModBus protocol for connection to a building management system (BMS); ● an RS232 serial-link communication card for communication with a modem and a remote-maintenance system; ● a USB communication card, ● an XML-Web (HTTP) communication card for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser. Shutdown and administration software shall be available in addition to the communication cards. 11. - Maintainability ● All power components shall be accessible from the front. ● UPS design shall provide maximum mean time between failure (MTBF) and minimum mean time to repair (MTTR). ● For optimum safety during servicing, an external maintenance bypass ( systems with more than 2 UPS units) shall be available to completely isolate the UPS. 11.1 - Local and remote diagnostics and monitoring - E. Services ● The UPS shall be equipped with a self-test system to check operation of the system as a whole. The electronic UPS control and monitoring assembly shall therefore be fully micro-processor based, t●hus doing away with all potentiometer settings and making possible: ● auto-compensation of component drift; ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote); ● system components shall be ready for customer type (level 2) or manufacturer type (level 4) electronic mediation of services and/or monitoring. 12 - Standards and tests 12.1 - Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. ● IEC 60146-4: UPS - Performance. ● IEC 62040-1 and EN 62040-1: UPS - Safety. ● IEC 62040-2 and EN 62040-2 level B: UPS - Electromagnetic compatibility. ● IEC 62040-3 and EN 62040-3: UPS - Performance. ● IEC 60950 / EN 60950: Safety of IT equipment, including electrical business equipment. ● IEC 61000-2-2: Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. ● IEC 61000-3-4: Limits for harmonic current emissions (equipment input current > 16 A/ph). ● IEC 61000-4: EMC - Electrical fast transient/burst immunity. ● EN 55011 and EN 55022: Limits and methods of measurement of radio interference characteristics of industrial, scientific and medical (ISM) radio-frequency equipment - Level B conducted and radiated emissions. ● IEC 439: Low-voltage switchgear and controlgear assemblies. ● IEC 60529: Degrees of protection provided by enclosures (IP Code). ● ISO 3746: Sound power levels. ● CE marking. What is more, the equipment must comply with environmental-protection standards, with production taking place on premises certified ISO 14001. 12.2 - Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 12 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 13 - Test procedures and quality system 13.1 - Test procedures The UPS manufacturer shall provide proof of a stringent Quality Assurance programme. In particular, the main equipment manufacturing stages shall be sanctioned by appropriate tests such as: ● incoming components inspection, discrete subassembly testing; ● complete functional checks on the final product. Equipment shall undergo on-load burn-in before leaving the factory. Final inspection and adjustments shall be documented in a report drawn up by the supplier’s Quality Inspection department. ISO 9001 or 9002 certification of the production site is compulsory. 13.2 - Quality system The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. 14 - Services 14.1 - Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. Predictive-maintenance operations on consumable subassemblies / components. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 14.2 - Technical competency ● customer operators: the supplier shall offer a level 2 training program. ● service personnel: the supplier shall ensure that service personnel are qualified for level 4. 14.3 - Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorized agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). ● The supplier shall offer a remote technical-support service based on a network of experts and a system capable of handling emergencies 24/365 around the world. 14.4 - System start-up ● The system and equipment shall be started up on site by the supplier or its authorized agent. The procedure shall include on-site acceptance during which checks will be carried out on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 13 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 14.5 - Replacement parts ● The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 14.6 Recycling and renovation/substitution ● At the end of the UPS service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 15 - Warranty The rectifier/charger and inverter subassemblies shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. 16 - Installation services Required services include: ● supply of the UPS and any accessory parts or elements; ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site; ● connections between the battery and the UPS; ● connection of the normal AC source to the rectifier/charger; ● connection of the bypass AC source to the input transformer or bypass input; ● connection of the load circuits to the UPS output. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 14 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) 17 - Electrical diagram Fig. N+1 redundancy with two identical integrated parallel UPS units. Fig. N+1 redundancy with mulitple integrated parallel UPS units (all identical) and an external maintenance bypass cabinet. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 15 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) Appendix. Check list Type of UPS kVA Total rated power (kVA) at PF 0.8 Identical parallel-connected units units rated including redundant units units kVA each kVA and one maintenance bypass cabinet APC by Schneider Electric Manufacturer Range of products double conversion yes no 380 or 440 or 415 V ± 15% yes no Input frequency 50 or 60 Hz ± 10% yes no Input-current distortion THDI upstream ≤ 4% yes no Input power factor PF > 0.94 yes no sealed lead acid in a cabinet yes no yes no Operating mode (IEC 62040-2) Rectifiers Three-phase input voltage at Pn Battery Type Standard Other Service life years yes no Backup time minutes yes no yes no yes no yes no yes no yes no yes no yes no Battery management and protection Temperature correction Measurement of actual backup time, depending on: load, temperature, age Cold start on battery power Protection against deep discharge with circuit-breaker opening Protection against self-discharge Charge-current limiting 0.05 C10 to 0.1 C10 (depending on the battery) Self-tests APC by Schneider Electric 05/2009 edition ch. 6 – spec. 3b - p. 16 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) Inverters Volts yes no ± 3% yes no Steady-state conditions ± 1% yes no Voltage transients ± 5% (load from 0 to 100 or 100 to 0%) yes no Output voltage distortion at Pn THDU ph-N < 5% yes no Hz yes no ± 0.5 Hz yes no ± 0.25 Hz to 2 Hz yes no Frequency synchronization with an external source ± 8% of rated frequency yes no Overload capacity 125% In for 10 minutes yes no 150% In for 1 minute yes no Current limiting 233% In for 1 second yes no Crest factor up to 3:1 yes no Static bypass yes no Short-circuit withstand of static bypass 10 In - 20 milliseconds yes no Maintenance bypass yes no > 93.5% at Pn and > 92,5% at Pn/2 yes no Display measurements, status, events yes no Controls ON, OFF, EPO terminal block yes no Status indications Communication Audio alarm, LEDs yes no Programmable relay card yes no EPO terminal block yes no 3 slots for communication cards yes no Ethernet SNMP card yes no RS485 JBus/Modbus card yes no RS232 U-Talk card yes no XML-Web card yes no Supervision software yes no yes no Three-phase output voltage with neutral Adjustable to Output frequency Variation in output frequency adjustable from Static switches Efficiency Normal mode User interface Options Administration software APC by Schneider Electric With shutdown management 05/2009 edition ch. 6 – spec. 3b - p. 17 Specification guide no. 3b Parallel, three-phase UPS system, 160 to 800 kVA (cont.) Certification Certified standards and tests see list in section 12.1 yes no Certification of performance TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier Level 4 NFX 060-010 yes no Diagnostics and monitoring Remote yes no Technical support International yes no Access to power components through front yes no Installable against wall yes no yes no Services Operation, Maintainability Availability Availability of original replacement parts Around the world t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes no Emergency services yes no Renovation / substitution programmes yes no yes no Maintenance programmes Eco-design and manufacturing APC by Schneider Electric Preventive ISO 14001 site 05/2009 edition ch. 6 – spec. 3b - p. 18 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA 1. UPS definition ............................................................................................................................... 2 1.1. Purpose................................................................................................................................ 2 1.2. Brief description ................................................................................................................... 2 2. Operating principles ..................................................................................................................... 2 2.1. Normal operation ................................................................................................................. 2 2.2. Operation on battery power .................................................................................................. 2 2.3. Battery recharging ................................................................................................................ 2 2.4. Transfer to bypass AC source.............................................................................................. 2 2.5. UPS maintenance ................................................................................................................ 2 2.6. Battery maintenance ............................................................................................................ 3 2.7. Cold start (normal AC source absent) .................................................................................. 3 3. Sizing and general characteristics .............................................................................................. 3 3.1. Technology .......................................................................................................................... 3 3.2. Rating................................................................................................................................... 3 3.3. Battery backup time ............................................................................................................. 3 3.4. Types of loads accepted ...................................................................................................... 3 3.5. PFC sinusoidal-current input rectifier ................................................................................... 3 3.6. Output without a transformer................................................................................................ 3 3.6. Efficiency.............................................................................................................................. 3 3.7. Noise level ........................................................................................................................... 3 4. AC sources ................................................................................................................................... 4 4.1. Normal AC source................................................................................................................ 4 4.2. Bypass AC source ............................................................................................................... 4 5. Electrical characteristics .............................................................................................................. 4 5.1. Rectifier and charger ............................................................................................................ 4 5.2. Battery.................................................................................................................................. 4 5.3. Inverter ................................................................................................................................. 5 5.4. Automatic bypass ................................................................................................................. 5 5.5. Discrimination ...................................................................................................................... 6 5.6. System earthing arrangements (SEA).................................................................................. 6 6. Mechanical characteristics .......................................................................................................... 7 6.1. Mechanical structure ............................................................................................................ 6 6.2. Dimensions .......................................................................................................................... 6 6.3. Connection ........................................................................................................................... 6 6.4. Ventilation ............................................................................................................................ 6 6.5. Safety ................................................................................................................................... 7 7. Environment conditions ............................................................................................................... 7 7.1. UPS (not including battery) .................................................................................................. 7 8. Protection....................................................................................................................................... 7 8.1. UPS...................................................................................................................................... 7 8.2. Rectifier and charger ............................................................................................................ 7 8.3. Inverter ................................................................................................................................. 7 8.4. Battery.................................................................................................................................. 7 9. Battery management ..................................................................................................................... 8 9.1. Self-tests .............................................................................................................................. 8 9.2. Measurement of actual backup time .................................................................................... 8 9.3. Battery digital management ................................................................................................. 8 9.4. Block by block monitoring .................................................................................................... 8 10. User interface and communication ............................................................................................ 8 10.1. User interface ..................................................................................................................... 8 10.2. Communication .................................................................................................................. 9 11. Maintainability.............................................................................................................................. 10 12. Standards and tests .................................................................................................................... 10 12.1. Standards........................................................................................................................... 10 12.2. Certification of conformity................................................................................................... 11 13. Quality system and test procedures .......................................................................................... 11 14. Services ........................................................................................................................................ 11 14.1. Maintenance ...................................................................................................................... 11 14.2. Technical competency ....................................................................................................... 11 14.3. Functional components - organisation of supplier services ................................................ 12 14.4. System start-up .................................................................................................................. 12 14.5. Replacement parts ............................................................................................................. 12 14.6. Recycling and renovation ................................................................................................... 12 15. Warranty ....................................................................................................................................... 12 16. Further services........................................................................................................................... 12 17. Electrical diagram........................................................................................................................ 13 Appendix. Check list ......................................................................................................................... 14 APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 1 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) 1. UPS definition 1.1. Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying, putting into operation and maintaining an Uninterruptible Power Supply (referred to as a UPS hereinafter). The UPS shall be designed to supply dependable electric power to: 1.2. Brief description The UPS shall be a single UPS, operating in double-conversion mode (also called on-line mode); it shall be a VFItype UPS (as per standard IEC 62040-2), made up of the following components, described in detail in this specification: ● rectifier ● battery charger ● inverter ● battery ● automatic bypass (via a static switch) ● manual bypass (for maintenance) ● user and communications interface ● battery management system ● any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. 2. Operating principles The UPS shall operate in double-conversion mode as indicated below. 2.1. Normal operation (normal AC source available) The rectifier shall supply the inverter and the charger with DC current. The inverter shall continuously supply the load with backed up electrical energy and the charger shall float charge the battery. 2.2. Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter shall continue to supply the load from battery power without interruption or disturbance, within the limits imposed by the battery backup time. 2.3. Battery recharging (normal AC source restored) When the normal AC source is restored, the rectifier shall again power the inverter, without interruption or disturbance to the load, while the charger automatically recharges the battery. 2.4. Transfer to bypass AC source In case of a major overload or if the UPS shuts down, the static switch shall instantaneously transfer the load, without a break in the supply of power, to the bypass AC source if it is available and within tolerances. Transfer of the load back to the UPS output, synchronised with the bypass AC source, shall be automatic or manual. During transfer, the load shall not suffer an outage or disturbance in the supply of power. On request, the UPS system may automatically transfer the load with a micro-interruption (adjustable from 15 to 1000 ms) if a major fault occurs on the UPS system and if synchronisation with the bypass source has not been established. 2.5. UPS maintenance For maintenance purposes, the UPS shall include a mechanical manual bypass system with one-button operation. For personnel safety during servicing or testing, this system shall be designed to isolate the UPS while continuing to supply power to the load from the bypass AC source. The UPS shall also include a device making it possible to isolate the rectifier and the charger from the normal AC source. All power and control electronics shall be accessible from the front of the UPS. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 2 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) 2.6. Battery maintenance For safe maintenance on the battery, the system shall include a circuit breaker to isolate the battery from the rectifier, the charger and the inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.7. Cold start (normal AC source absent) The battery shall be capable of starting the UPS if the normal AC source is absent and continue supplying power to the load within the specified backup time. Cold start on battery power shall be possible on the condition that the system shall have started at least once on normal AC power. 3. Sizing and general characteristics 3.1. Technology UPS technology shall be based on IGBT transistors for all the power converters (rectifier, charger and inverter with variable chopping frequency). 3.2. Rating The UPS shall be sized to continuously supply a load of…[250 / 300 / 400 / 500] kVA at a power factor of 0.9. 3.3. Battery backup time The battery backup time in the event of a normal AC source outage shall be _______ minutes, for a load power factor of 0.9. The battery shall be designed for a service life of …[ 10 / 12 ]…years. It shall be selected and sized correspondingly, for a load power factor of 0.9. 3.4. Types of loads accepted The UPS shall accept high crest factors (3:1) without derating (kW) to ensure correct operation with computer loads and loads where the leading power factor can reach 0.9. The total harmonic voltage distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU downstream ph/ph ≤ 3% for non-linear loads. 3.5. PFC sinusoidal-current input rectifier The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of guide IEC 61000-3-4. The PFC input rectifier using sinusoidal-current IGBTs shall have the following performance levels: ● total harmonic current distortion (THDI) upstream of the rectifier not exceeding 5%, ● input power factor (PF) greater than 0.99 from 50% load upwards. 3.6. Output without a transformer To reduce losses, dimensions and weight, the UPS output shall be of the transformerless type and the neutral shall be recreated electronically. 3.7. Efficiency Overall efficiency (between the rectifier input and the UPS output) shall be greater than or equal to: ● 94.5% from 50% load to full rated load (In). The UPS shall be capable of operating on the bypass AC source if it is within tolerance (ECO mode) with a minimum efficiency of: ● 97% in ECO mode. It shall be possible to set the shift to operation in ECO mode to automatic or manual. If the bypass AC source is not longer within tolerances, transfer without a break to normal mode shall be automatic. 3.8. Noise level The noise level, measured as per standard ISO3746, shall be less than …[70 dBA (for 250, 300, 400 kVA)] [72 dB (for 500 kVA)]. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 3 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) 4. AC sources 4.1. Normal AC source (rectifier input) The normal AC source supplying the UPS shall, under normal operating conditions, have the following characteristics: ● rated voltage: 380 - 400 or 415 Volts rms at full rated load Pn ● input voltage range: 250 V (at 30% load) to 470 V ●number of phases: 3, a neutral is not required ●frequency: Hz ± 10% 4.2. Bypass AC source (automatic-bypass input) The characteristics of the bypass AC source supplying the UPS in the event of an inverter shutdown (maintenance, failure) or an overload (short-circuit, very high inrush current) shall be the following: ● voltage: / volts, ± 10% ● number of phases: 3 ph + N + earth (a non-distributed neutral is possible) ● frequency: Hz ± 8% (adjustable up to ± 2 Hz) Outside these tolerances, it shall be possible to supply the load, but in downgraded mode. 5. Electrical characteristics 5.1. Rectifier and charger 5.1.1. Power supply The PFC rectifier, drawing sinusoidal current, shall be supplied by the normal AC source, without a neutral. It shall provide power for the load as well as charge or float charge the battery. The battery charger shall be supplied by the rectifier to avoid transmitting any AC fluctuations to the battery. 5.1.2. Inrush current A device shall be provided to limit inrush currents. When AC power fails and during genset start, the rectifier shall limit the power drawn by implementing a walk-in for ten seconds. 5.1.3. Phase sequence A device shall check that the phase sequence is correct to protect the power system from the effects of incorrect connections. The device shall also check the bypass AC input. 5.1.4. Operating mode The standard charger shall be sufficient to charge the battery rapidly. For a backup time of …[5 / 10 / 15 / 20 / 30] … minutes, battery recharging shall take less than …[4 / 6 / 7 / 8 / 9 hours]… (values after discharge to Pn/2 and recovery of 90% of total battery charge for a recent battery). 5.1.5. Input power factor The performance level shall be that mentioned in section 3.5, i.e. PF > 0.99. 5.1.6. Charger regulation and monitoring The battery recharge system shall include independent regulation and monitoring devices to ensure conformity with standard NFC 58311. The battery recharge voltage shall be a function of the ambient temperature in the battery room. 5.2. Battery The UPS shall be equipped with a battery of the …[sealed lead-acid type, mounted and wired in a cabinet identical in aspect to that of the UPS]…[sealed lead-acid type, mounted on shelves] …[vented lead-acid type mounted on racks]… and shall have a service life of …[10 / 12]… years. The battery shall be sized to ensure a continuous supply to the inverter for at least …[5 / 10 / 15 / 20 / 30…]… minutes, in the event the normal AC source fails, given that the inverter is at full rated load, i.e. kVA for a power factor PF = 0.9. Sizing calculations shall assume an ambient temperature between 0°C and 35°C. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 4 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) 5.3. Inverter The inverter shall be sized to supply a rated load of …[250 / 300 / 400 / 500]… kVA at 0.9 PF and shall satisfy the specifications listed below. 5.3.1. Output voltage ● Rated voltage …[380 / 400 / 415 / 440]… volts rms, adjustable via the user interface (see section 10), within tolerances of +/- 3% in order to take into account voltage drops in the cables. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions Variations in the rated voltage shall be limited to ± 2% for a balanced load between 0 and 100% of the rated load, whatever the voltage level on the normal AC source and the DC voltage level, within the limits defined in sections 4.1 and 5.1.4. ● Voltage variations for load step changes Output voltage transients shall not exceed ± 1% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 100 milliseconds. ● Unbalanced conditions For a load unbalance between phases, the variation in the output voltage shall be less than 1%. 5.3.2. Output frequency ● Rated frequency -50 or 60 Hz. ● Variations in the free-running frequency - ± 0.5 Hz. 5.3.3. Synchronisation with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions in section 5.4), the inverter output voltage shall be synchronised with the bypass source voltage whenever possible. To that end, during normal operation, a synchronisation system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within adjustable tolerances of 0.5% to 8% with respect to the rated frequency). ● Synchronisation with an external source It shall be possible to synchronise with all types of external source. ● Autonomous operation following loss of synchronisation with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronisation, regulating its own frequency to within ± 0.02 Hz. When bypass power returns to within tolerances, the inverter shall automatically resynchronise. ● Variation in frequency per unit time To avoid transmitting to the inverter any excessive frequency variations on the bypass AC source when it is within tolerances, inverter frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s or 2 Hz/s (user defined). 5.3.4. Overload and short-circuit capacity The UPS shall be capable of supplying for at least: ● 10 minutes a load representing 125% of the rated load ● 1 minutes a load representing 135 % of the rated load ● 30 second a load representing 150% of the rated load. ● For the specified power rating of …[ 250 / 300 / 400 / 500 ]… kVA, the inverter shall be capable of current limiting to a peak capacity of ... [300% / 250% / 250% / 275%] ... for 150 ms to allow highly disturbed transient operating states without transferring the load to the bypass. ● The overload capacity shall be capable of taking into account temperature conditions for more than ten minutes, by allowing a continuous, 10% overload when the temperature is less than or equal to 20°C. 5.3.5. Higher power ratings for lower temperatures It shall be possible to increase the power rating when the temperature is less than 35°C. The rating c an be raised by +3% for 30°C, +5% for 25°C and +8% for 20°C. 5.4. Automatic bypass 5.4.1. Load transfer to the automatic bypass The UPS shall be equipped with an automatic bypass comprising a static switch. Instantaneous transfer of the load from the inverter to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.2 and that the inverter is synchronised. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 5 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) Transfer shall take place automatically in the event of a major overload or an internal inverter fault. Manually initiated transfer shall also be possible. If the bypass power is outside the specified tolerances or is not synchronised with the inverter, automatic transfer of the load from the inverter to bypass power shall be disabled or shall take place after a calibrated interruption adjustable from 15 to 1000 ms. 5.4.2. Static-switch protection The static switch shall be equipped with an RC filter for protection against switching overvoltages and lightning strikes. 5.4.3. Static-switch withstand For the specified power rating of …[ 500 / 400 / 300 / 250 ]… kVA, the static switch shall be capable of handling an overcurrent of …[ 16 / 16 / 21 / 25 ]…. times the rated current of the UPS to facilitate discrimination within the electrical installation. 5.5. Discrimination and short-circuit capacity If the bypass power is within the tolerances specified in section 4.2, the presence of the static switch shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the inverter. To ensure tripping in a selective manner, the available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated inverter current). If the bypass source is outside the specified tolerances, the inverter on its own shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of short-circuit. 5.6. System earthing arrangements (SEA) The UPS shall be compatible with the following system earthing arrangements (SEA): ●upstream source SEA: …[TT/ IT / TNS / TNC]… ●downstream installation SEA: …[ TT/ IT / TNS / TNC ]… If the upstream and downstream SEAs are different, galvanic isolation shall be provided on the normal and bypass lines. 6. Mechanical characteristics 6.1. Mechanical structure The UPS and batteries shall be installed in cabinet(s) with an [ IP 20 / IP 32 ] degree of protection (standard IEC 60529). Access to the subassemblies making up the system shall be exclusively through the front. 6.2. Dimensions The UPS shall require as little floor space as possible. To gain space, it shall be possible to install the UPS with the back to the wall or back to back with another UPS unit. 6.3. Connections To facilitate connections, all terminal blocks must be easily accessible from the front when the UPS is installed with the back to the wall. Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible through the bottom without requiring a false floor. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 12. The cables shall comply with the standards listed in section 12 and be mounted in compliance with the safety stipulations in section 6.6. 6.4. Ventilation System cooling shall be by forced-air ventilation. To facilitate layout of cabinets (particularly when installed back to the wall), air input shall be through the front and bottom, exit through the top. All power electronics shall be equipped with a redundant ventilation system including fault detection. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 6 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) 6.5. Safety For the safety of maintenance personnel, the cabinet shall be provided with a manually operated mechanical bypass designed to isolate the rectifier, charger, inverter and static switch while continuing to supply the load from the bypass AC source. The UPS shall be equipped with a terminal block for reception of an external EPO order resulting in opening of the battery circuit breaker and shutdown of all converters. 7. Environment conditions 7.1. UPS (not including battery) 7.1.1. Operation The UPS, not including the battery, shall be capable of operating under the following environmental conditions without loss of performance: ● temperature range during continuous operation: 0°C to 35°C ● maximum temperature: 40°C for eight hours ● recommended temperature range: + 20°C to + 25°C ● maximum relative humidity: 95% at 25°C ● maximum altitude without derating: 1000 m. 7.1.2. Storage The UPS, not including the battery, shall be designed for storage under the following conditions: ● ambient temperature range: - 10°C to + 45°C. 8. Protection 8.1. UPS The UPS shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2. Rectifier and charger The rectifier shall automatically shutdown if the temperature exceeds the limits specified in section 7.1.1. The charger shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer or if the temperature exceeds the limits specified in section 7.1.1. 8.3. Inverter Inverters shall self-protect against overloads and short-circuits, irrespective of the operating mode (AC power or battery power). 8.4. Battery 8.4.1. Protection against deep discharge and self-discharge The UPS shall comprise a device designed to protect the battery against deep discharges, taking into account the characteristics of the discharge cycles, with isolation of the battery by a circuit breaker. 8.4.2. Independent regulation and monitoring systems A regulation system shall regulate the battery voltage and the charge current. A second system, independent of the regulation, shall monitor the battery voltage and the charge current. Consequently, if the regulation system fails, the monitoring system steps in to shut down the charger and avoid overcharging. 8.4.3. Regulation of the battery voltage depending on the ambient temperature A temperature sensor adapts the charge voltage to the ambient temperature. This regulation system takes into account the chemical reaction and prolongs the battery service life. The permissible temperature range is set in the personalisation parameters. An alarm shall be issued for temperatures outside the permissible range. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 7 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) 9. Battery management Batteries are components whose service life is sensitive to operating conditions, i.e. particular care is required for their management. In addition to the protective systems indicated in section 8.4, battery management shall included the systems listed below. 9.1. Self-test The battery shall be equipped with a self-test that can be run: ● on request via a manual control ● automatically according to user-set time intervals. The self-test shall enable updating of battery parameters and detection of all abnormal conditions in view of preventive maintenance. 9.2. Measurement of actual backup time The battery function shall be equipped with the means to know at all times the real backup time available (AC power available) or remaining (AC power not available), taking into account the true load on the inverter, the battery temperature and battery ageing. 9.3. Digital battery monitoring The UPS shall be equipped with a system for battery digital management. Based on a number of parameters (percent load, temperature, battery type and age), the system shall control the battery charge voltage and continuously calculate: ● the true available backup time (section 9.2) ● the remaining service life. 9.4. Block by block monitoring To further optimise battery availability and service life, it shall be possible to equip the UPS with an optional system to continuously monitor all battery strings and display a block by block failure prediction. The system shall include the functions listed below. ● Continuous measurement of the voltage of each block. ● Continuous measurement of the internal resistance. ● Identification of faulty blocks (trend curves). ● Possibility of replacing individual blocks. ● Remoting of all information via Ethernet, dry contacts or JBus. 10. User interface and communication 10.1. User interface UPS operation shall be facilitated by a user interface comprising: ●a B&W graphical display ●ON and OFF control buttons (independent of the display) ●status indications with mimic panel. 10.1.1. Graphical display The mimic diagram shall enable display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass). It shall be capable of supervising a single UPS or a parallel system of up to eight UPS units with their SSC (static-switch cabinet). ● display of measurements It shall be possible to display the following measurements: - inverter output phase-to-phase voltages - inverter output currents - inverter output frequency - voltage across battery terminals - battery charge or discharge current - rectifier/charger input phase-to-phase voltages - rectifier/charger input currents - crest factor - active and apparent power - power factor of the load - battery temperature - battery percent charge - available backup time APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 8 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) - the remaining battery service life. ● display of status conditions and events It shall be possible to display the following indications: - load on battery power - load on UPS - load on automatic bypass - general alarm - battery fault - remaining battery backup time - low battery warning - bypass AC source outside tolerances - battery temperature. Additional information shall be provided in view of accelerating system servicing, as specified in section 11. ● display of operating graphs It shall be possible to display bargraphs of the measurements mentioned above on the screen over significant periods. ● statistics Number of overloads, number of transfers to battery power, cumulative time on battery power, maximum power levels, demand power levels. ● log of time-stamped events This function shall store in memory and make available, for automatic or manually initiated recall, time-stamped logs of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. It shall be possible to time stamp and store at least 2500 events. 10.1.2. Controls The UPS shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of the UPS, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● EPO terminal block The UPS shall be equipped with an emergency power off (EPO) terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of UPS units - opening of the static switches on the bypass line and of the battery circuit breaker - opening of an isolated dry contact on the programmable card. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. 10.1.3. Status indications with mimic panel Indication of status conditions shall be distinct of the graphic display. Three LEDs on the control panel indicate the following status conditions: ● load protected ● minor fault ● major fault. The mimic panel shall represent the UPS and indicate the status of the load supply using five two-colour (red and green) LEDs: ● load supplied (LED at UPS output on mimic panel) ● inverter on (inverter LED on mimic panel) ● operation on battery power (LED between battery and inverter on mimic panel) ● bypass activated (bypass LED on mimic panel) ● PFC rectifier on (rectifier LED on mimic panel). A buzzer shall warn the user of faults, malfunctions or operation on battery power. 10.2. Communication 10.2.1. Standard communication It shall be possible to remote the following controls, indications and measurements. To that end, the UPS shall have as standard equipment: ● a programmable card with four inputs and six outputs. 10.2.2. Communications options The UPS shall be designed to enable the extension of communications, without system shutdown, to the following types of cards: ● multi-standard communications card with two outputs: - an RS485 serial-link implementing the JBus/ModBus protocol for connection to a building management system (BMS) APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p. 9 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) - Ethernet 10/100 Mbps using one of the protocols below: XML-Web for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser SNMP for connection to a computer-network management system ● multi-standard communications card with three outputs: - the two outputs listed above - plus a modem output for communication with a tele-maintenance system. ● The UPS shall be detectable by supervision software for large UPS systems. ● Shutdown and administration software shall be available in addition to the communication cards. 11. Maintainability A manual bypass shall be available to completely isolate the UPS for maintenance purposes. 11.1. Local and remote diagnostics and monitoring - E. Services The UPS shall be equipped with a self-test system to check operation of the system as a whole each time it is started. To that end, the supply control/monitoring electronics shall offer: ● auto-compensation of component drift ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote); ● overall readiness for remote supervision services provided by the manufacturer. 12. Standards and tests 12.1. Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. A. Safety: ● IEC 60950-1 / EN 60950-1 Information technology equipment - Safety - Part: General requirements ● IEC 62040-1/ EN 62040-1 Uninterruptible power systems (UPS) - General and safety requirements for UPS. ● IEC 62040-3 / EN 1000-3 Uninterruptible power systems (UPS) - Method of specifying the test and performance requirements. ● IEC 60439 Low-voltage switchgear and controlgear assemblies. ● LV directive: 2006/95/EC B. Harmonics: ● IEC 61000-2-2 / EN 61000-2-2 Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. ● IEC 61000-3-2 / EN 61000-3-2 Limits for harmonic current emissions (equipment input current ≤ 16 A/ph). ● IEC 61000-3-4 / EN 61000-3-4 Limits for harmonic current emissions (equipment input current > 16 A/ph). ● IEC 61000-3-5 / EN 61000-3-5 Limitation of voltage fluctuations and flicker. ● EN 50160 Voltage characteristics of public networks. ● IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems. C. EMC: ● EN 50091-2 UPS - EMC. ● IEC 62040-2/ EN 62040-2 Uninterruptible power systems (UPS) - Electromagnetic compatibility (EMC) requirements. ● EMC Directive 2004/108/EC For equipment liable to cause or be affected by electromagnetic disturbances. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p.10 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) D. Quality: ● Design , production and servicing in compliance with standard ISO 9001 - quality organisation. E. Ecological environment: ● Manufacturing in compliance with standard ISO 14001. F. Acoustic noise ● ISO 3746 : Sound power levels. ● ISO 7779 / EN 27779 : Measurement of airborne noise emitted by computer and business equipment. What is more, the equipment shall comply with eco-design and eco-manufacturing criteria in view of sustainable development and to that end, the manufacturer shall be able to demonstrate: ● R&D and production on an ISO 14001 certified site ● manufacture with over 90% recyclable materials ● capacity to recover products at the end of their service life and provide proof of destruction by a certified organisation ● the environmental profile of the product, which shall be supplied with the sales offer. 12.2. Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). 13. Quality system and test procedures 13.1. Test procedures The manufacturer shall provide proof of a quality-assurance system. In particular, the main manufacturing steps must be subject to suitable tests such as: ● inspection of incoming components, tests on discrete subassemblies ● complete functional checks on termination of manufacture. The equipment shall be subject to burn-in under load conditions prior to shipping. Final checks and adjustments shall be recorded in a report drafted by the quality-inspection department of the supplier. Certification of the industrial facilities in compliance with ISO 9001 or 9002 shall be required. 13.2. Quality system The UPS must be designed using an ISO 9001 quality system and a dependability study to ensure maximum reliability. 14. Services 14.1. Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 14.2. Technical competency ● Customer operators: the supplier shall offer a level 2 training program. ● Service personnel: the supplier shall ensure that service personnel are qualified for level 4. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p.11 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) 14.3. Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorised agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). 14.4. System start-up The system and equipment shall be started up on site by the supplier or its authorised agent. The procedure shall include checks on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. 14.5. Replacement parts The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 14.6. Recycling and renovation/substitution At the end of the UPS service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 15. Warranty The rectifier, charger and inverter subassemblies shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. 16. Further services Required services include: ● supply of the UPS and any accessory parts or elements ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site ● connections between the battery and the UPS ● connection of the normal AC source to the rectifier/charger ● connection of the bypass AC source to the input transformer or bypass input ● connection of the load circuits to the UPS output. 17. Electrical diagram APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p.12 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) Battery Normal AC input Bypass AC input UPS Load Fig. UPS electrical diagram. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p.13 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) Appendix. Check list Type of UPS Total rated power (kVA) at PF 0.9 kVA kW Manufacturer Range of products Operating mode (IEC 62040-2) double conversion Operation as frequency converter yes no yes no Rectifier Input voltage range: 250 V to 470 V yes no 3-phase input without neutral yes no Phase sequence Check on phase sequence yes no Sinusoidal input current THDI upstream ≤ 5% with PFC rectifier yes no Input power factor PF > 0.99 with IGBT rectifier (from 50% load) yes no yes no No inrush or start-up current Rapid battery recharging Typical 10-min. backup time recharged in six hours or less yes no Voltage regulation ± 1% yes no yes no yes no yes no Independent regulation/monitoring systems for the charger Battery Type standard sealed lead acid in a cabinet other Service life years yes no Backup time minutes yes no Recharge as a function of the temperature yes no Measurement of actual backup time, depending on load, temperature, age yes no Cold start on battery power yes no Battery management and protection Protection against deep discharge with circuit-breaker opening yes no Charge-current limiting 0.05 C10 to 0.1 C10 (depending on battery yes no Self-tests yes no Measurement of real backup time yes no Block by block monitoring yes no Prediction on end of service life yes no APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p.14 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) Inverter Volts yes no ± 3% yes no Steady-state conditions ± 1% yes no Voltage transients ± 5% (load from 0 to 100% or 100 to 0%) yes no Output voltage distortion at Pn THDU < 3% yes no Unbalanced conditions Voltage variation < 1% yes no yes no ± 0.5 Hz yes no - 0.25 Hz to + 2 Hz yes no Frequency synchronisation with an external source ± 0.5% to ± 8% of rated frequency yes no Overload capacity 125% In for 10 minutes yes no 165% In for 1 minute yes no Current limiting yes 250% to 300% In for 150 milliseconds (e.g. 300% for 250 kVA and 250% for 300 kVA) no Crest factor up to 3:1 yes no Automatic bypass With static switch yes no Short-circuit withstand of static switch 16 to 25 In for 20 ms, depending on rating yes (e.g. 25 In for 250 kVA / 16 In for 500 kVA) no Built-in manual bypass Mechanical (for maintenance) yes no Normal mode > 94.5% from 50% load yes no ECO mode > 97 % yes no selection of operating language from 19 yes no personalisation menu with password yes no display measurements, status, events, graphs yes no event log 2500 time-stamped events yes no bargraphs power levels, backup time yes no statistics % time on battery power, number of transfers to battery power, average percent load, etc. yes no Controls ON, OFF, EPO terminal block yes no Status indications with mimic panel Audio alarm, LEDs yes no Three-phase output voltage adjustable within limits Hz Output frequency Variation in output frequency adjustable from Bypass functions Efficiency User interface Graphical display APC by Schneider Electric 05/2009 edition ch. 6 – spec. 4a - p.15 Specification guide no. 4a Single UPS, three-phase, 250 to 500 kVA (cont.) Communication Programmable relay card yes no EPO terminal block yes no Card with two outputs JBus/ModBus RS485 + Ethernet 10/100 yes no Card with three outputs Same as 2-output card + modem +NMTC yes no yes no with shutdown management yes no Certified standards and tests See list in section 12.1 yes no Performance certification TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier level 4 NFX 060-010 yes no Diagnostics and monitoring remote yes no Technical support international yes no yes no hot-swap cards yes no around the world yes no Options Supervision software Administration software Certification Services Operation, Maintainability Access to power components through front Access to communication through front Availability Availability of original replacement parts t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes yes no no Emergency services yes no Renovation / substitution programmes yes no Maintenance programmes APC by Schneider Electric preventive predictive 05/2009 edition ch. 6 – spec. 4a - p.16 Specification guide no. 4b Modular UPS system with external bypass, 250 to 4000 kVA* * Maximum power rating for eight 500 kVA UPS units Contents 1. UPS definition ............................................................................................................................... 2 1.1. Purpose................................................................................................................................ 2 1.2. Brief description ................................................................................................................... 2 2. Operating principles ..................................................................................................................... 2 2.1. Normal operation ................................................................................................................. 2 2.2. Operation on battery power .................................................................................................. 2 2.3. Battery recharging ................................................................................................................ 2 2.4. Transfer to bypass AC source.............................................................................................. 2 2.5. UPS maintenance ................................................................................................................ 2 2.6. Battery maintenance ............................................................................................................ 3 2.7. Cold start (normal AC source absent) .................................................................................. 3 3. Sizing and general characteristics .............................................................................................. 3 3.1. Technology .......................................................................................................................... 3 3.2. Rating................................................................................................................................... 3 3.3. Battery backup time ............................................................................................................. 3 3.4. Types of loads accepted ...................................................................................................... 3 3.5. PFC sinusoidal-current input rectifier ................................................................................... 3 3.6. Output without a transformer................................................................................................ 3 3.6. Efficiency.............................................................................................................................. 3 3.7. Noise level ........................................................................................................................... 3 4. AC sources ................................................................................................................................... 4 4.1. Normal AC source................................................................................................................ 4 4.2. Bypass AC source ............................................................................................................... 4 5. Electrical characteristics .............................................................................................................. 5 5.1. Rectifier and charger ............................................................................................................ 5 5.2. Battery.................................................................................................................................. 5 5.3. Inverter ................................................................................................................................. 5 5.4. Automatic bypass ................................................................................................................. 6 5.5. External bypass ................................................................................................................... 7 5.6. Discrimination ...................................................................................................................... 7 5.7. System earthing arrangements (SEA).................................................................................. 7 6. Mechanical characteristics .......................................................................................................... 7 6.1. Mechanical structure ............................................................................................................ 7 6.2. Modular design .................................................................................................................... 7 6.3. Dimensions .......................................................................................................................... 7 6.4. Connection ........................................................................................................................... 7 6.5. Ventilation ............................................................................................................................ 7 7. Environment conditions ............................................................................................................... 8 8. Protection....................................................................................................................................... 8 8.1. Modular UPS units ............................................................................................................... 8 8.2. Rectifier and charger ............................................................................................................ 8 8.3. Inverter ................................................................................................................................. 8 8.4. Battery.................................................................................................................................. 8 9. Battery management ..................................................................................................................... 9 9.1. Self-tests .............................................................................................................................. 9 9.2. Measurement of actual backup time .................................................................................... 9 9.3. Battery digital management ................................................................................................. 9 9.4. Block by block monitoring .................................................................................................... 9 10. User interface and communication ............................................................................................ 9 10.1. User interface ..................................................................................................................... 9 10.2. Communication .................................................................................................................. 10 11. Maintainability.............................................................................................................................. 11 12. Standards and tests .................................................................................................................... 11 12.1. Standards........................................................................................................................... 11 12.2. Certification of conformity................................................................................................... 12 13. Quality system and test procedures .......................................................................................... 12 14. Services ........................................................................................................................................ 12 14.1. Maintenance ...................................................................................................................... 12 14.2. Technical competency ....................................................................................................... 12 14.3. Functional components - organisation of supplier services ................................................ 13 14.4. System start-up .................................................................................................................. 13 14.5. Replacement parts ............................................................................................................. 13 14.6. Recycling and renovation ................................................................................................... 13 15. Warranty ....................................................................................................................................... 13 16. Further services........................................................................................................................... 13 17. Electrical diagram........................................................................................................................ 14 Appendix. Check list ......................................................................................................................... 15 APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 1 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* * Maximum power rating for eight 500 kVA UPS units 1. UPS definition 1.1. Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying, putting into operation and maintaining an Uninterruptible Power Supply system (referred to as a UPS system hereinafter). The UPS system shall be designed to supply dependable electric power to: 1.2. Brief description The UPS system shall be made up of …[2 / 3 / 4 / 5 / 6 / 7 / 8]… identical, parallel-connected modular UPS units, all having the same power rating. Each modular UPS unit shall operate in double-conversion mode and shall be of the VFI-type as per standard IEC 62040-2. The system shall … [ not provide redundancy ] …[ include 1 / 2 / 3 redundant modular UPS units among the total ]. Each modular UPS unit shall have a rating of …[250 / 300 / 400 / 500]… kVA and shall be made up of the following components, described in detail in this specification: ● rectifier ● battery charger ● inverter ● battery ● automatic bypass (via a static switch) ● user and communications interface ● battery management system. What is more, the UPS system shall include: ● a common external bypass for all the modular UPS units, that shall be installed in a cabinet ● any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. 2. Operating principles The UPS system shall operate in double-conversion mode as indicated below. 2.1. Normal operation (normal AC source available) The rectifier of each modular UPS unit shall supply its inverter and charger. Each modular UPS unit shall continuously contribute, in parallel with the other modular UPS units via a common bus, to supplying the load with backed up electrical energy and the charger shall float charge the battery. 2.2. Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter of each modular UPS unit shall continue to supply the load from battery power without interruption or disturbance, within the limits imposed by the battery backup time. 2.3. Battery recharging (normal AC source restored) When the normal AC source is restored, the rectifier of each modular UPS unit shall again power its inverter, without interruption or disturbance to the load, while the charger automatically recharges the battery. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 2 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 2.4. Transfer to bypass AC source ( system without redundancy) The system does not provide redundancy. The inverters of the [2 / 3 / 4 / 5 / 6 / 7 / 8] modular UPS units shall operate in parallel to supply the load. The automatic bypasses of each modular UPS unit shall be connected to the same bypass AC source. Voluntary shutdown or a major fault on a modular UPS unit shall result in automatic transfer, without interruption, of the load to the bypass AC source via the bypass of each modular UPS unit, including the unit shut down, if the AC bypass is within tolerances and synchronised with the inverter outputs. On request, the UPS system may automatically transfer the load with a micro-interruption (adjustable from 15 to 1000 ms) if synchronisation with the bypass source has not been established, to enable operation in downgraded mode and enhance supply of power to the load. In all cases, to ensure load transfer in complete safety, the system shall simultaneously control all the static switches. ………………………………………………………………………………………………………………………………….. ( system with redundancy) The modular UPS units shall operate in parallel, providing redundancy and sharing the load. Redundancy shall be of the ….[n+1] [n+2] [n+3]… type, i.e. …[1] [2] [3]… modular UPS units will be redundant out of the total of …[2 / 3 / 4 / 5 / 6 / 7 / 8]… modular UPS units. The automatic bypasses of each modular UPS unit shall be connected to the same bypass AC source. ● If a major fault occurs on a modular UPS unit, it shall automatically disconnect and its inverter shall no longer supply the load. Given that the system is redundant, the remaining modular UPS units shall continue to supply the load. However the initial level of redundancy shall be reduced by one unit, falling from …[n+1 to non-redundant operation] [n+2 to n+1] [n+3 to n+2]. ● If another modular UPS unit shuts down, the resulting level of redundancy shall determine whether inverter operation is still possible. ● Loss of redundancy is in all cases signalled by an alarm. ● If redundancy has been lost, shutdown of another modular UPS unit shall result in automatic transfer, without interruption, of the load to the bypass AC source via the bypass of each modular UPS unit, including the units shut down, if the AC bypass is within tolerances and synchronised with the inverter outputs. On request, the UPS system may automatically transfer the load with a micro-interruption (adjustable from 15 to 1000 ms) if synchronisation with the bypass source has not been established, to enable operation in downgraded mode and enhance supply of power to the load. In all cases, to ensure load transfer in complete safety, the system shall simultaneously control all the static switches. 2.5. UPS-system maintenance All power and control electronics of the modular UPS units making up the UPS system shall be accessible from the front of the UPS. For maintenance purposes, the UPS system shall include an external, mechanical, manual bypass system with one-button operation, common to all modular UPS units. For personnel safety during servicing or testing, this system shall be designed to isolate the UPS system while continuing to supply power to the load from the bypass AC source. The UPS shall also include a device making it possible to isolate the rectifier and the charger of each modular UPS unit from the normal AC source. ( system with redundancy) In a redundant system, with the above device, it shall be possible to shut down a modular UPS unit and isolate its charger and inverter for maintenance, with the other inverters in the UPS system continuing to supply the load. 2.6. Battery maintenance For safe maintenance, the battery of each modular UPS unit shall include a circuit breaker to isolate the battery from the rectifier, the charger and the inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.7. Cold start (normal AC source absent) The battery of each modular UPS unit shall be capable of starting the UPS if the normal AC source is absent and continue supplying power to the load within the specified backup time. Cold start on battery power shall be possible on the condition that the system shall have started at least once on normal AC power. 3. Sizing and general characteristics 3.1. Technology The UPS system technology shall be based on IGBT transistors for all the power converters (rectifier, charger and inverter with variable chopping frequency). APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 3 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 3.2. Rating The UPS system shall be sized to continuously supply a load of kVA at a power factor of 0.9. The UPS system shall be made up of …[2 / 3 / 4 / 5 / 6 / 7 / 8]… identical, parallel-connected modular UPS units, each having a power rating of …[250 / 300 / 400 / 500]… kVA. The total installed power rating shall be kVA. It shall be possible to use …[1] [2] [3]… modular UPS units for redundancy. 3.3. Battery backup time The battery backup time in the event of a normal AC source outage shall be _______ minutes, for a load power factor of 0.9. The battery of each modular UPS unit shall be designed for a service life of …[10 / 12]… years. It shall be selected and sized correspondingly, for a load power factor of 0.9. 3.4. Types of loads accepted The UPS system shall accept high crest factors (3:1) without derating (kW) to ensure correct operation with computer loads and loads where the leading power factor can reach 0.9. The total harmonic voltage distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU downstream ph/ph ≤ 3% for non-linear loads. 3.5. PFC sinusoidal-current input rectifiers The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of guide IEC 61000-3-4. The PFC input rectifiers of the modular UPS units, using sinusoidal-current IGBTs, shall have the following performance levels: ● total harmonic current distortion (THDI) upstream of the rectifier not exceeding 5% ● input power factor (PF) greater than 0.99 from 50% load upwards. 3.6. Outputs without a transformer To reduce losses, dimensions and weight, the output of each UPS unit shall be of the transformerless type and the neutral shall be recreated electronically. 3.7. Efficiency Overall efficiency (between the rectifier inputs and the UPS output) shall be greater than or equal to: ● 94.5% from 50% load to full rated load (In). 3.8. Noise level The noise level, measured as per standard ISO3746, shall be less than …[70 dBA (for 250, 300, 400 kVA)] [72 dB (for 500 kVA)]. 4. AC sources 4.1. Normal AC source (rectifier input) The normal AC source supplying the UPS system shall, under normal operating conditions, have the following characteristics: ● rated voltage: 380 - 400 or 415 Volts rms at full rated load Pn ● input voltage range: 250 V (at 30% load) to 470 V ● number of phases: 3, a neutral is not required ● frequency: Hz ± 10% 4.2. Bypass AC source (automatic-bypass input) The characteristics of the bypass AC source supplying the UPS system in the event of an inverter shutdown (maintenance, failure) or an overload (short-circuit, very high inrush current) shall be the following: APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 4 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units ● voltage: / volts, ± 10% ● number of phases: 3 ph + N + earth (a non-distributed neutral is possible) ● frequency: Hz ± 8% (adjustable up to ± 2 Hz) Outside these tolerances, it shall be possible to supply the load, but in downgraded mode. 5. Electrical characteristics 5.1. Rectifier and charger 5.1.1. Power supply The PFC rectifier of each modular UPS unit, drawing sinusoidal current, shall be supplied by the normal AC source, without a neutral. It shall provide power for the load as well as charge or float charge the battery. The battery charger shall be supplied by the rectifier to avoid transmitting any AC fluctuations to the battery. Each unit is independent in terms of its input module, i.e. one unit can operate on battery power, the others on AC power. 5.1.2. Inrush current A device shall be provided to limit the inrush currents of each charger. When AC power fails and during genset start, the rectifier shall limit the power drawn by implementing a walk-in for ten seconds. 5.1.3. Sequential start An adjustable device shall make it possible to stagger start-up of the PFC rectifiers when the normal AC source returns to within tolerances (transfer from battery power to normal AC power). By ensuring sequential start, this device shall avoid overloading a genset picking up the supply to all the rectifiers. 5.1.4. Phase sequence A device shall check that the phase sequence is correct to protect the power system from the effects of incorrect connections. 5.1.5. Operating mode The standard charger of each modular UPS unit shall be sufficient to charge the battery rapidly. For a backup time of …[5 / 10 / 15 / 20 / 30] … minutes, battery recharging shall take less than …[4 / 6 / 7 / 8 / 9 hours]… (values after discharge to Pn/2 and recovery of 90% of total battery charge for a recent battery). 5.1.6. Input power factor The performance level shall be that mentioned in section 3.5, i.e. PF > 0.99. 5.1.7. Charger regulation and monitoring The battery recharge system shall include independent regulation and monitoring devices to ensure conformity with standard NFC 58311. The battery recharge voltage shall be a function of the ambient temperature in the battery room. 5.2. Battery Each modular UPS unit shall be equipped with its own battery of the …[sealed lead-acid type, mounted and wired in a cabinet identical in aspect to that of the UPS]…[sealed lead-acid type, mounted on shelves] …[vented leadacid type mounted on racks]… and shall have a service life of …[10 / 12]… years. The battery shall be sized to ensure a continuous supply to the inverter for at least …[5 / 10 / 15 / 20 / 30…]… minutes, in the event the normal AC source fails, given that the inverter is at full rated load, i.e. kVA for a power factor PF = 0.9. Sizing calculations shall assume an ambient temperature between 0°C and 35°C. 5.3. Inverter Each inverter shall be sized to supply a rated load of …[250 / 300 / 400 / 500]… kVA at 0.9 PF and shall satisfy the specifications listed below. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 5 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 5.3.1. Output voltage ● Rated voltage …[380 / 400 / 415 / 440]… volts rms, adjustable via the user interface (see section 10), within tolerances of +/- 3% in order to take into account voltage drops in the cables. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions Variations in the rated voltage shall be limited to ± 2% for a balanced load between 0 and 100% of the rated load, whatever the voltage level on the normal AC source and the DC voltage level, within the limits defined in sections 4.1 and 5.1.5. ● Voltage variations for load step changes Output voltage transients shall not exceed ± 1% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 100 milliseconds. ● Unbalanced conditions For a load unbalance between phases, the variation in the output voltage shall be less than 1%. 5.3.2. Output frequency ● Rated frequency -50 or 60 Hz. ● Variations in the free-running frequency - ± 0.5 Hz. 5.3.3. Synchronisation with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions in section 5.4), the inverter output voltage shall be synchronised with the bypass source voltage whenever possible. To that end, during normal operation, a synchronisation system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within adjustable tolerances of 0.5% to 8% with respect to the rated frequency). ● Synchronisation with an external source It shall be possible to synchronise with all types of external source. ● Autonomous operation following loss of synchronisation with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronisation, regulating its own frequency to within ± 0.02 Hz. When bypass power returns to within tolerances, the inverter shall automatically resynchronise. ● Variation in frequency per unit time To avoid transmitting to the inverter any excessive frequency variations on the bypass AC source when it is within tolerances, inverter frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s or 2 Hz/s (user defined). 5.3.4. Overload and short-circuit capacity The UPS system shall be capable of supplying for at least: ● 10 minutes a load representing 125% of the rated load ● 1 minutes a load representing 135 % of the rated load ● 30 second a load representing 150% of the rated load. ● For the specified power rating of …[ 250 / 300 / 400 / 500 ]… kVA, the inverter shall be capable of current limiting to a peak capacity of ... [300% / 250% / 250% / 275%] ... for 150 ms to allow highly disturbed transient operating states without transferring the load to the bypass. ● The overload capacity shall be capable of taking into account temperature conditions for more than ten minutes, by allowing a continuous, 10% overload when the temperature is less than or equal to 20°C. 5.3.5. Higher power ratings for lower temperatures It shall be possible to increase the power rating when the temperature is less than 35°C. The rating c an be raised by +3% for 30°C, +5% for 25°C and +8% for 20°C. 5.4. Automatic bypass 5.4.1. Load transfer to the automatic bypass Each modular UPS unit in the UPS system shall be equipped with an automatic bypass comprising a static switch. The automatic bypasses of each modular UPS unit shall be connected to the same bypass AC source. Instantaneous transfer of the load from the inverter to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.2 and that the inverter is synchronised. Transfer shall take place automatically in the event of a major overload or an internal inverter fault. Manually initiated transfer shall also be possible. If the bypass power is outside the specified tolerances or is not synchronised with the inverter, automatic transfer of the load from the inverter to bypass power shall take place after a calibrated interruption adjustable from 15 to 1 000 milliseconds. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 6 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 5.4.2. Static-switch protection The static switch shall be equipped with an RC filter for protection against switching overvoltages and lightning strikes. 5.4.3. Automatic-bypass withstand For the specified power rating of …[ 500 / 400 / 300 / 250 ]… kVA for each modular UPS units, each static switch shall be capable of handling an overcurrent of …[ 16 / 16 / 21 / 25 ]…. times the rated current of the modular UPS unit to facilitate discrimination within the electrical installation. 5.5. External manual bypass (for maintenance) The UPS system shall include an external, mechanical, manual bypass system with one-button operation, common to all modular UPS units. This system shall be designed to isolate the UPS system while continuing to supply power to the load from the bypass AC source and shall be sized to supply the full load. 5.6. Discrimination and short-circuit capacity If the bypass power is within the tolerances specified in section 4.2, the static switches shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the inverter. Each static switch shall be sized to handle the overcurrent corresponding to the short-circuit power divided by the number of modular UPS units in parallel and any redundant units. To ensure tripping in a selective manner, the total available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated inverter current). If the bypass source is outside the specified tolerances, all the inverters in operation shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of short-circuit. 5.7. System earthing arrangements (SEA) The UPS system shall be compatible with the following system earthing arrangements (SEA): ● upstream source SEA: …[TT/ IT / TNS / TNC]… ● downstream installation SEA: …[TT/ IT / TNS / TNC]… If the upstream and downstream SEAs are different, galvanic isolation shall be provided on the normal and bypass lines. 6. Mechanical characteristics 6.1. Mechanical structure The inverter and batteries of each modular UPS unit shall be installed in cabinet(s) with an [ IP 20 / IP 32 ] degree of protection (standard IEC 60529). Access to the subassemblies making up the system shall be exclusively through the front. 6.2. Modular design The UPS system shall be designed to allow the installed power to be easily increased on site by connection of additional modular UPS units, either to meet new load requirements or to enhance system availability by introducing or increasing redundancy. This transformation shall be possible directly on site, without returning the equipment to the factory and without causing excessive system downtime. 6.3. Dimensions The UPS system shall require as little floor space as possible. To gain space, it shall be possible to install the modular UPS units with the back to the wall or back to back. 6.4. Connections To facilitate connections, all terminal blocks must be easily accessible from the front when the modular UPS units are installed with the back to the wall. Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible through the bottom without requiring a false floor. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 12. The cables shall comply with the standards listed in section 12 and be mounted in compliance with the safety stipulations in section 6.6. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 7 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 6.5. Ventilation Cooling of each modular UPS unit shall be by forced-air ventilation. To facilitate layout of the modular UPS units (particularly when installed back to the wall), air input shall be through the front and bottom, exit through the top. All power electronics shall be equipped with a redundant ventilation system including fault detection. 7. Environment conditions UPS (not including batteries) 7.1. Operation The UPS, not including the batteries, shall be capable of operating under the following environmental conditions without loss of performance: ● temperature range during continuous operation: 0°C to 35°C ● maximum temperature: 40°C for eight hours ● recommended temperature range: + 20°C to + 25°C ● maximum relative humidity: 95% at 25°C ● maximum altitude without derating: 1000 m. 7.1. Storage The UPS, not including the batteries, shall be designed for storage under the following conditions: ● ambient temperature range: - 10°C to + 45°C. 8. Protection 8.1. Modular UPS units Each modular UPS unit in the UPS system shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2. Rectifiers and chargers Each rectifier and the corresponding battery charger shall accept external orders provoking automatic shutdown in the following cases: ● EPO (emergency power off), in which the battery circuit breaker also opens ● if the temperature exceeds the limits specified in section 7.1.1. The rectifier shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer or if the temperature exceeds the limits specified in section 7.1.1. 8.3. Inverter The load shall be protected against overvoltages resulting from a loss of voltage regulation at the output of the inverters. Each inverter (and the corresponding rectifier and charger) shall shut down automatically when the DC voltage reaches the minimum voltage specified by the battery manufacturer. In the event of an overload exceeding system capacity (AC bypass absent), each inverter shall be equipped with an automatic shutdown system to protect its power circuits. A load short-circuit shall provoke the static shutdown of each inverter without fuse destruction. 8.4. Battery 8.4.1. Protection against deep discharge The UPS system shall comprise a device designed to protect each battery against deep discharges, taking into account the characteristics of the discharge cycles, with isolation of the batteries by a circuit breaker. 8.4.2. Independent regulation and monitoring systems A regulation system shall regulate the battery voltage and the charge current of each modular UPS unit. A second system, independent of the regulation, shall monitor the battery voltage and the charge current. Consequently, if the regulation system fails, the monitoring system steps in to shut down the charger and avoid overcharging. 8.4.3. Regulation of the battery voltage depending on the ambient temperature A temperature sensor adapts the charge voltage of each charger to the ambient temperature. This regulation system takes into account the chemical reaction and prolongs the battery service life. The permissible temperature range is set in the personalisation parameters. An alarm shall be issued for operation of the given rectifier outside the permissible range. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 8 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 9. Battery management Batteries are components whose service life is sensitive to operating conditions, i.e. particular care is required for their management. In addition to the protective systems indicated in section 8.4, battery management shall included the systems listed below. 9.1. Self-test The battery shall be equipped with a self-test that can be run: ● on request via a manual control ● automatically according to user-set time intervals. The self-test shall enable updating of battery parameters and detection of all abnormal conditions in view of preventive maintenance. 9.2. Measurement of actual backup time The battery function of each modular UPS unit shall be equipped with the means to know at all times the real backup time available (AC power available) or remaining (AC power not available) for the battery of the unit, taking into account the true load on the inverter, the battery temperature and battery ageing. 9.3. Digital battery monitoring Each modular UPS unit shall be equipped with a system for battery digital management. Based on a number of parameters (percent load, temperature, battery type and age), the system shall control the battery charge voltage and continuously calculate: ● the true available backup time (section 9.2) ● the remaining service life. 9.4. Block by block monitoring To further optimise availability and service life of the batteries, it shall be possible to equip the UPS system with an optional system to continuously monitor all battery strings and display a block by block failure prediction. The system shall include the functions listed below. ● Continuous measurement of the voltage of each block. ● Continuous measurement of the internal resistance. ● Identification of faulty blocks (trend curves). ● Possibility of replacing individual blocks. ● Remoting of all information via Ethernet, dry contacts or JBus. 10. User interface and communication 10.1. User interface UPS-system operation shall be facilitated by a user interface on each of the modular UPS units, comprising: ● a B&W graphical display ● ON and OFF control buttons (independent of the display) ● status indications with mimic panel. 10.1.1. Graphical display The mimic diagram shall enable display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass). It shall be capable of supervising a given modular UPS unit or a parallel system (up to eight UPS units with the external bypass). ● display of measurements It shall be possible to display the following measurements for any one of the modular UPS units or for the entire system: - inverter output phase-to-phase voltages - inverter output currents - inverter output frequency - voltage across battery terminals - battery charge or discharge current - rectifier/charger input phase-to-phase voltages - rectifier/charger input currents - crest factor - active and apparent power - power factor of the load - battery temperature - battery percent charge APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p. 9 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units - available backup time - the remaining battery service life. ● display of status conditions and events It shall be possible to display the following indications: - load on battery power - load on UPS - load on automatic bypass - general alarm - battery fault - remaining battery backup time - low battery warning - bypass AC source outside tolerances - battery temperature. Additional information shall be provided in view of accelerating system servicing, as specified in section 11. ● display of operating graphs It shall be possible to display bargraphs of the measurements mentioned above on the screen over significant periods. ● statistics Number of overloads, number of transfers to battery power, cumulative time on battery power, maximum power levels, demand power levels. ● log of time-stamped events This function shall store in memory and make available, for automatic or manually initiated recall, time-stamped logs of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. It shall be possible to time stamp and store at least 2500 events. 10.1.2. Controls Each modular UPS unit shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of the UPS, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● EPO terminal block The UPS shall be equipped with an emergency power off (EPO) terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of UPS units - opening of the static switches on the bypass line and of the battery circuit breaker - opening of an isolated dry contact on the programmable card. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. 10.1.3. Status indications with mimic panel Indication of status conditions shall be distinct of the graphic display. Three LEDs on the control panel on each modular UPS unit indicate the following status conditions: ● load protected by the modular UPS unit ● minor fault ● major fault. The mimic panel shall represent the modular UPS unit and indicate the status of the load supply using five twocolour (red and green) LEDs: ● load supplied (LED at UPS output on mimic panel) ● inverter on (inverter LED on mimic panel) ● operation on battery power (LED between battery and inverter on mimic panel) ● bypass activated (bypass LED on mimic panel) ● PFC rectifier on (rectifier LED on mimic panel). A buzzer shall warn the user of faults, malfunctions or operation on battery power. 10.2. Communication 10.2.1. Standard communication It shall be possible to remote the following controls, indications and measurements. To that end, each modular UPS unit in the UPS system shall have as standard equipment: ● a programmable card with four inputs and six outputs. 10.2.2. Communications options The UPS system shall be designed to enable the extension of communications, without system shutdown, to the following types of cards that may be installed on each modular UPS unit: ● multi-standard communications card with two outputs: APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p.10 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units - an RS485 serial-link implementing the JBus/ModBus protocol for connection to a building management system (BMS) - Ethernet 10/100 Mbps using one of the protocols below: XML-Web for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser SNMP for connection to a computer-network management system ● multi-standard communications card with three outputs: - the two outputs listed above - plus a modem output for communication with a tele-maintenance system. ● The UPS shall be detectable by supervision software for large UPS systems. ● Shutdown and administration software shall be available in addition to the communication cards. 11. Maintainability A common external bypass shall be available to completely isolate the UPS. 11.1. Local and remote diagnostics and monitoring - E. Services The UPS shall be equipped with a self-test system to check operation of the system as a whole each time it is started. To that end, the supply control/monitoring electronics shall offer: ● auto-compensation of component drift ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote); ● overall readiness for remote supervision services provided by the manufacturer. 12. Standards and tests 12.1. Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. A. Safety: ● IEC 60950-1 / EN 60950-1 Information technology equipment - Safety - Part: General requirements ● IEC 62040-1/ EN 62040-1 Uninterruptible power systems (UPS) - General and safety requirements for UPS. ● IEC 62040-3 / EN 1000-3 Uninterruptible power systems (UPS) - Method of specifying the test and performance requirements. ● IEC 60439 Low-voltage switchgear and controlgear assemblies. ● LV directive: 2006/95/EC B. Harmonics: ● IEC 61000-2-2 / EN 61000-2-2 Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. ● IEC 61000-3-2 / EN 61000-3-2 Limits for harmonic current emissions (equipment input current ≤ 16 A/ph). ● IEC 61000-3-4 / EN 61000-3-4 Limits for harmonic current emissions (equipment input current > 16 A/ph). ● IEC 61000-3-5 / EN 61000-3-5 Limitation of voltage fluctuations and flicker. ● EN 50160 Voltage characteristics of public networks. ● IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems. C. EMC: ● EN 50091-2 UPS - EMC. ● IEC 62040-2/ EN 62040-2 Uninterruptible power systems (UPS) - Electromagnetic compatibility (EMC) requirements. ● EMC Directive 2004/108/EC For equipment liable to cause or be affected by electromagnetic disturbances. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p.11 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units D. Quality: ● Design , production and servicing in compliance with standard ISO 9001 - quality organisation. E. Ecological environment: ● Manufacturing in compliance with standard ISO 14001. F. Acoustic noise ● ISO 3746 : Sound power levels. ● ISO 7779 / EN 27779 : Measurement of airborne noise emitted by computer and business equipment. What is more, the equipment shall comply with eco-design and eco-manufacturing criteria in view of sustainable development and to that end, the manufacturer shall be able to demonstrate: ● R&D and production on an ISO 14001 certified site ● manufacture with over 90% recyclable materials ● capacity to recover products at the end of their service life and provide proof of destruction by a certified organisation ● the environmental profile of the product, which shall be supplied with the sales offer. 12.2. Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). 13. Quality system and test procedures 13.1. Test procedures The manufacturer shall provide proof of a quality-assurance system. In particular, the main manufacturing steps must be subject to suitable tests such as: ● inspection of incoming components, tests on discrete subassemblies ● complete functional checks on termination of manufacture. The equipment shall be subject to burn-in under load conditions prior to shipping. Final checks and adjustments shall be recorded in a report drafted by the quality-inspection department of the supplier. Certification of the industrial facilities in compliance with ISO 9001 or 9002 shall be required. 13.2. Quality system The UPS must be designed using an ISO 9001 quality system and a dependability study to ensure maximum reliability. 14. Services 14.1. Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 14.2. Technical competency ● Customer operators: the supplier shall offer a level 2 training program. ● Service personnel: the supplier shall ensure that service personnel are qualified for level 4. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p.12 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 14.3. Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorised agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). 14.4. System start-up The system and equipment shall be started up on site by the supplier or its authorised agent. The procedure shall include checks on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. 14.5. Replacement parts The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 14.6. Recycling and renovation/substitution At the end of UPS-system service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 15. Warranty The components making up each modular UPS unit (rectifier, charger and inverter subassemblies) shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. 16. Further services Required services include: ● supply of the UPS and any accessory parts or elements ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site ● connections between the batteries and the modular UPS units in the UPS system ● connection of the normal AC source to the rectifiers ● connection of the normal AC source to the AC bypass ● connection of the load circuits to the UPS output. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p.13 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units 17. Electrical diagram Bypass AC input Battery Normal AC input Battery Normal AC input Battery Normal AC input External maintenance bypass Load Fig. Electrical diagram of the UPS system with three modular UPS units and an external manual bypass. APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p.14 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units Appendix. Check list Type of modular UPS unit making up the parallel UPS system Rated power (kVA) at PF 0.9 kVA kW Manufacturer Range of products yes no yes no Up to three redundant units (n+3) yes no Alarm signalling loss of redundancy within the UPS system yes no Operating mode (IEC 62040-2) double conversion KVA max Parallel connection of up to 8 modular UPS units Rectifier Input voltage range: 250 V to 470 V yes no 3-phase input without neutral yes no Phase sequence Check on phase sequence yes no Sinusoidal input current THDI upstream ≤ 5% with PFC rectifier yes no Input power factor PF > 0.99 with IGBT rectifier (from 50% load) yes no yes no No inrush or start-up current Rapid battery recharging Typical 10-min. backup time in ≤ 6 hours yes no Voltage regulation ± 1% yes no yes no yes no yes no Independent regulation/monitoring systems for the charger Battery Type standard sealed lead acid in a cabinet other Service life years yes no Backup time minutes yes no Recharge as a function of the temperature yes no Measurement of actual backup time, depending on: load, temperature, age yes no Cold start on battery power yes no Battery management and protection Protection against deep discharge with circuit-breaker opening yes no Charge-current limiting 0.05 C10 to 0.1 C10 depending on battery yes no Self-tests yes no Measurement of real backup time yes no Block by block monitoring yes no Prediction on end of service life yes no APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p.15 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units Inverter Volts yes no ± 3% yes no Steady-state conditions ± 1% yes no Voltage transients ± 5% (load from 0 to 100% or 100 to 0%) yes no Output voltage distortion at Pn THDU < 3% yes no Unbalanced conditions Voltage variation < 1% yes no yes no ± 0.5 Hz yes no - 0.25 Hz to + 2 Hz yes no Frequency synchronisation with an external source ± 0.5% to ± 8% of rated frequency yes no Overload capacity 125% In for 10 minutes yes no 165% In for 1 minute yes no Current limiting 300% In for 150 milliseconds yes no Crest factor up to 3:1 yes no Automatic bypass of each UPS With static switch yes no Short-circuit withstand of static switch 10 to 25 In for 20 ms, depending on rating yes (e.g. 25 In at 250 kVA / 16 In at 500 kVA) no Manual bypass Via shared external bypass (for maintenance) yes no > 94.5% from 50% load yes no selection of operating language from 19 yes no personalisation menu with password yes no display measurements, status, events, graphs yes no event log 2 500 time-stamped events yes no bargraphs power levels, backup time yes no statistics % time on battery power, number of transfers to battery power, average percent load, etc. yes no Controls ON, OFF, EPO terminal block yes no Status indications with mimic panel Audio alarm, LEDs yes no Three-phase output voltage adjustable within limits Hz Output frequency Variation in output frequency adjustable from Bypass functions Efficiency Overall efficiency of UPS system User interface Graphical display APC by Schneider Electric 02/2009 edition ch. 6 – spec. 4b - p.16 Specification guide no. 4b Modular UPS with external bypass, 250 to 4000 kVA* (cont.) * Maximum power rating for eight 500 kVA UPS units Communication Programmable relay card yes no EPO terminal block yes no Card with two outputs JBus/ModBus RS485 + Ethernet 10/100 yes no Card with three outputs Same as the two-output card + a modem yes no yes no with shutdown management yes no Certified standards and tests See list in section 12.1 yes no Performance certification TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier level 4 NFX 060-010 yes no Diagnostics and monitoring remote yes no Technical support international yes no yes no hot-swap cards yes no around the world yes no Options Supervision software Administration software Certification Services Operation, Maintainability Access to power components through front Access to communication through front Availability Availability of original replacement parts t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes yes no no Emergency services yes no Renovation / substitution programmes yes no Maintenance programmes APC by Schneider Electric preventive predictive 02/2009 edition ch. 6 – spec. 4b - p.17 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA Contents 1 - UPS definition ................................................................................................................................. 2 1.1 - Purpose ................................................................................................................................ 2 1.2 - Brief description .................................................................................................................... 2 2 - Operating principle ......................................................................................................................... 2 2.1 - Normal operation .................................................................................................................. 2 2.2 - Operation on battery power................................................................................................... 2 2.3 - Battery recharge ................................................................................................................... 2 2.4 - Transfer to bypass AC source............................................................................................... 3 2.5 - UPS maintenance ................................................................................................................. 3 2.6 - Battery maintenance ............................................................................................................. 3 2.7 - Cold start (AC power absent) ................................................................................................ 3 3 - Sizing and general characteristics ................................................................................................ 3 3.1 - Technology ........................................................................................................................... 3 3.2 - Rating ................................................................................................................................... 3 3.3 - Battery backup time .............................................................................................................. 3 3.4 - Types of loads accepted ....................................................................................................... 3 3.5 - Limitation of harmonics upstream of the UPS ....................................................................... 4 3.6 - Efficiency .............................................................................................................................. 4 3.7 - Noise level ............................................................................................................................ 4 4 - AC sources...................................................................................................................................... 4 4.1 - Normal AC source................................................................................................................. 4 4.2 - Bypass AC source ................................................................................................................ 4 5 - Electrical characteristics................................................................................................................ 4 5.1 - Rectifier and charger ............................................................................................................. 4 5.2 - Batteries................................................................................................................................ 5 5.3 - Inverter ................................................................................................................................. 5 5.4 - Static bypass ........................................................................................................................ 6 5.5 - Discrimination and short circuit capacity ............................................................................... 6 5.6 - System earthing arrangement ............................................................................................... 6 6 - Mechanical characteristics ............................................................................................................ 7 6.1 - Mechanical structure ............................................................................................................. 7 6.2 - Scalable design .................................................................................................................... 7 6.3 - Dimensions ........................................................................................................................... 7 6.4 - Connections .......................................................................................................................... 7 6.5 - Ventilation ............................................................................................................................. 7 6.6 - Safety ................................................................................................................................... 7 7 - Environment conditions ................................................................................................................. 7 7.1 - UPS (not including battery) ................................................................................................... 7 8 - Protection ........................................................................................................................................ 8 8.1 - UPS ...................................................................................................................................... 8 8.2 - Rectifier/chargers .................................................................................................................. 8 8.3 - Inverters ................................................................................................................................ 8 8.4 - Batteries................................................................................................................................ 8 9 - Battery management ...................................................................................................................... 8 9.1 – Self-test ................................................................................................................................ 8 9.2 - Measurement of actual backup time ..................................................................................... 8 9.3 - Digital battery management .................................................................................................. 8 9.4 - Block by block monitoring ..................................................................................................... 9 10 - User interface and communication ............................................................................................. 9 10.1 - User interface ..................................................................................................................... 9 10.2 - Communication ................................................................................................................... 10 11 - Maintainability..................................................................................................................................... 11 12 - Standards and tests .......................................................................................................................... 11 12.1 - Standards ................................................................................................................................. 11 12.2 - Certification of conformity ......................................................................................................... 11 13 - Test procedures and quality system ................................................................................................ 11 14 - Services ............................................................................................................................................... 12 14.1 - Maintenance ............................................................................................................................. 12 14.2 - Technical competency .............................................................................................................. 12 14.3 - Functional components ............................................................................................................. 12 14.4 - System start-up......................................................................................................................... 12 14.5 - Replacement parts .................................................................................................................... 12 14.6 - Recycling and renovation .......................................................................................................... 12 15 - Warranty .............................................................................................................................................. 12 16 - Installation services ........................................................................................................................... 13 17 - Electrical diagram ............................................................................................................................... 13 Appendix. Check list.................................................................................................................................. 14 APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.1 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 1 - UPS definition 1.1 - Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying, putting into operation and maintaining an Uninterruptible Power Supply (referred to as a UPS in the rest of this document). The UPS shall be designed to supply dependable electric power to: For information purposes MTBF in hours Single-UPS unit with static bypass 475 000 Non availability 2.1x10-5 1.2 - Brief description The UPS shall be a single-UPS unit, operating in double-conversion mode (also called on-line mode); it shall be a VFI-type UPS (as per standard IEC 62040-2), made up of the following components, described in detail in this specification: ● rectifier; ● battery charger; ● inverter; ● battery; ● static bypass (via a static switch); ● manual maintenance bypass; ● user and communications interface; ● battery management system; ● any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. The UPS shall ensure continuity of electric power to the load within the specified tolerances, without interruption upon failure or deterioration of the normal AC source (utility power) for a maximum protection time determined by the capacity of the backup batteries installed. 2 - Operating principle The double-conversion UPS (also called on-line) shall operate as defined below. 2.1 - Normal operation (normal AC source available) The rectifier supplies the inverter with DC current while the charger simultaneously float charges the battery. The load is continuously supplied with dependable electrical power by the inverter. 2.2 - Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter shall continue to supply the load from battery power without interruption or disturbance, within the limits imposed by the specified battery backup time. 2.3 - Battery recharge (normal AC source restored) When the normal AC source is restored, the rectifier shall again power the inverter, without interruption or disturbance to the load, while the charger automatically recharges the battery. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.2 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 2.4 - Transfer to bypass AC source In the event of an overload exceeding system capabilities or UPS shutdown, the static bypass switch shall instantaneously transfer the load to the bypass AC source without interruption, on the condition that bypass power is available and within tolerances. Transfer of the load back to the UPS-unit output, synchronised with the bypass AC source, shall be automatic or manual. During transfer, the load shall not suffer an outage or disturbance in the supply of power. On request, the UPS system may automatically transfer the load with a micro-interruption if a major fault occurs on the UPS system and if synchronisation with the bypass source has not been established. It shall be possible to set the duration of this micro-interruption. 2.5 - UPS maintenance For maintenance purposes, the UPS shall include a mechanical maintenance bypass system with one-button operation. For personnel safety during servicing or testing, this system shall be designed to isolate the UPS while continuing to supply power to the load from the bypass AC source. The UPS shall also include a device making it possible to isolate the rectifiers and the chargers from the normal AC source. Furthermore, all electronic components shall be accessible from the front of the UPS. 2.6 - Battery maintenance For safe maintenance on the battery, the system shall include a circuit breaker to isolate the battery from the rectifier, the charger and the inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.7 - Cold start (normal AC source absent) The battery shall be capable of ensuring UPS start-up even if normal AC power is not available and continuing operation within the specified back-up time (start on battery power shall be possible on the condition that the system was already started with AC power present). 3 - Sizing and general characteristics 3.1 - Technology The UPS shall be based on IGBT technology with built-in thermal monitoring and a free-frequency chopping mode to dynamically optimise efficiency and power quality. 3.2 - Rating The UPS shall be sized to continuously supply a load of …[800 / 900]… kVA. 3.3 - Battery backup time The battery backup time in the event of a normal AC source outage shall be _______ minutes, for a load power factor of 0.8. Battery service life shall be equal to at least …[ 10 / 12 ]…years. It shall be selected and sized correspondingly, for a load power factor of 0.8. 3.4 - Types of loads accepted The UPS shall accept high crest factors (3:1) without derating to ensure correct operation with computer loads. The total harmonic voltage distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU downstream ph/ph ≤ 3 % and ph/N ≤ 4% for linear loads. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.3 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 3.5 - Limitation of harmonics upstream of the UPS The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of guide IEC 61000-3-4. To that end, it shall be possible to equip each rectifier/charger input with a filter of the type …[compensated LC / non-compensated LC / with contactor / double-bridge / phase shifting]…capable of limiting the total harmonic distortion of the current (THDI) upstream to < 7%. If necessary, it shall be possible to use an electronic active filtering system to obtain, at the normal AC input, the following levels, constant from 50% to 100% load: ● total harmonic current distortion (THDI) upstream of the rectifier/charger not exceeding 4%; ● input power factor (pf) greater than 0.95. 3.6 - Efficiency Overall efficiency shall be greater than or equal to 94% at full rated load (In). 3.7 - Noise level The noise level for each unit, measured as per standard ISO 3746, shall be less than 72 dBA. 4 - AC sources The UPS shall be designed to receive power from the sources listed below. 4.1 - Normal AC source (rectifier input) The normal AC source supplying the UPS shall, under normal operating conditions, have the following characteristics: ● rated voltage: 380, 400 or 415 volts rms at full rated load Pn; ● number of phases: 3; ● frequency: Hz ± 10%. 4.2 - Bypass AC source (static-bypass input, if separate from rectifier input) The bypass power supplying the UPS in the event of an inverter shutdown (maintenance, failure) or an overload (short-circuit, heavy inrush currents, etc.) shall have the following characteristics: ● voltage: / volts, ± 10%; ● number of phases: 3 + N + earth; (a non-distributed neutral is possible); Hz ± 5% (adjustable up to ± 2 Hz). ● frequency: Outside these tolerances, it shall be possible to supply the load, but in downgraded mode. 5 - Electrical characteristics 5.1 - Rectifier and charger 5.1.1 - Supply The rectifier and charger module shall be supplied via the normal AC input. It must be capable of operating without a neutral (see section 4 "AC sources"). 5.1.2 - Inrush current A device shall be provided to limit inrush currents. When AC power fails and during genset start, the rectifier shall gradually limit the power it draws over a 10-second walk-in ramp. 5.1.3 - Battery-current limiting For long battery life, an electronic device shall automatically limit the charging current to the maximum value specified by the battery supplier (0.1 x C10 for a sealed lead-acid battery). 5.1.4 - Operating mode The standard charger shall be sized to recharge the battery rapidly: a battery with a backup time of…[5 / 10 minutes in less than 11 hours]… (following a discharge to Pn/2 to recover 90% of backup time). APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.4 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 5.1.6 - Input power factor The required level of performance is indicated in section 3.5 "Limitation of harmonics upstream of the UPS". 5.1.7 - Voltage regulation Rectifier/charger regulation shall take into account the ambient temperature of the battery and shall ensure DC output voltage fluctuations of less than 1% irrespective of load and AC input voltage variations (within the limits specified in section 4.1 “Normal AC source”). 5.2 - Batteries Each UPS unit shall be equipped with its own battery of the …[sealed lead-acid type, factory mounted and wired in a cabinet identical to that of the UPS,] … [sealed lead-acid type, mounted on shelves,]…[vented lead-acid type, mounted on a rack,]... with a service life equal to at least …[10 / 12]… years . Each battery shall be sized to ensure continuity in the supply of power to the corresponding inverter for at least …[8 / 10 / 15 / 30 …]… minutes, in the event of a normal AC source failure, with the inverter operating at full rated load, i.e. kVA at a power factor (pf) of 0.8. Sizing calculations shall assume an ambient temperature between 0° C and 35° C The UPS shall include devices to ensure: ● effective battery protection (see section 8.4 "Protection - Battery"); ● battery management (see section 9 "Battery management"). 5.3 - Inverter The inverter shall be sized to supply a rated load of …[ 800 / 900 ]… kVA at [ 0.8 / 0.9 ] pf and shall satisfy the specifications listed below. 5.3.1 - Output voltage ● Rated voltage …[ 380 / 400 / 415 ]… volts rms, adjustable via the user interface (see section 10), within tolerances of +/- 0.5%. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions The variation in the rated voltage shall be limited to ± 2% for a balanced load between 0 and 100% of the rated power, irrespective of normal AC input and DC voltage levels, within the limits specified in section 4.1 “Normal AC source” and 5.1.4 “Rectifier/charger - Operating modes and DC-voltage levels”. ● Voltage variations for load step changes Output voltage transients shall not exceed ± 0.5% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 100 milliseconds. ● Unbalanced load conditions For a load unbalance between phases, the output voltage variation shall be less than 1.5%. 5.3.2 - Output frequency ● Rated frequency - 50 or 60 Hz. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.5 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 5.3.3 - Synchronisation with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions below in section 5.4 "Static-bypass"), the inverter output voltage shall be synchronised with the bypass source voltage whenever possible. To that end, during normal operation, a synchronisation system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within adjustable tolerances of ± 0.5 Hz with respect to the rated frequency). ● Synchronisation with an external source It shall be possible to synchronise with all types of external source. ● Autonomous operation following loss of synchronisation with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronisation, regulating its own frequency to within ± 0.02 Hz. When bypass power returns to within tolerances, the inverter shall automatically resynchronise. ● Variation in frequency per unit time To avoid transmitting to the inverter any excessive frequency variations on the bypass AC source when it is within tolerances, inverter frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s or 2 Hz/s (user defined). 5.3.4 - Overload capacity The UPS shall be capable of supplying for at least: ● 1 minute a load representing 150% of the rated load. If necessary, the UPS shall operate as a generator (current limiting) with a peak capacity of 212% for 150 milliseconds, to allow highly disturbed transient operating states (high overloads, very high crest factors, etc.) without transferring the load to the bypass. 5.4 - Static bypass 5.4.1 - Load transfer to the static bypass The UPS shall be equipped with a static bypass comprising a static switch. Instantaneous transfer of the load from the inverter to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.2 "Bypass AC source" and that the inverter is synchronised. Transfer shall take place automatically in the event of a major overload or an internal inverter fault. Manually initiated transfer shall also be possible. If the bypass power is outside the specified tolerances or is not synchronised with the inverter, automatic transfer of the load from the inverter to bypass power shall take place after a calibrated interruption of approximately 500 to 800 milliseconds. 5.4.2 - Static-switch protection The static switch shall be equipped with an RC filter for protection against switching overvoltages and lightning strikes. 5.5 - Discrimination and short-circuit capacity If the bypass power is within the tolerances specified in section 4.2 "Bypass AC source" section, the presence of the static switch shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the inverter. To ensure tripping in a selective manner, the available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated inverter current). If the bypass source is outside the specified tolerances, the inverter on its own shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of short-circuit. 5.6 - System earthing arrangement The UPS shall be compatible with the following system earthing arrangements: ● upstream source: …[ TT/ IT / TNS / TNC ]… ● downstream installation: …[ TT/ IT / TNS / TNC ]… If the upstream and downstream earthing arrangements are different, galvanic isolation shall be provided on the static-bypass line. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.6 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 6 - Mechanical characteristics 6.1 - Mechanical structure The UPS and batteries shall be installed in cabinet(s) with a degree of protection IP20 (standard IEC 60529). Access to the subassemblies making up the system shall be exclusively through the front. 6.2 - Scalable design The UPS shall be designed to allow the installed power to be easily increased on site by connection of additional UPS units, either to meet new load requirements or to enhance system availability by introducing redundancy. This transformation shall be possible directly on site, without returning the equipment to the factory and without causing excessive system downtime. 6.3 – Dimensions The UPS shall require as little floor space as possible. To gain space, it shall be possible to install the UPS with the back to the wall or back-to-back with another UPS. 6.4 - Connection To facilitate connections, all terminal blocks must be easily accessible from the front when the UPS is installed with the back to the wall. Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible through the bottom for a false floor. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 12 "Standards and tests". The cables shall comply with the standards listed in section 12 "Standards and tests" and be mounted in compliance with the stipulations in section 6.6 "Safety". The neutral conductor shall be oversized for any third-order harmonic currents and their multiples (the size of the neutral shall be 1.5 times that of each phase). 6.5 - Ventilation The UPS units shall be provided with forced-air cooling. To facilitate positioning of UPS units (back to the wall), ventilation shall take place through the top with an air intake on the front. 6.6 - Safety For the safety of maintenance personnel, the cabinet shall be provided with a manually operated mechanical bypass designed to isolate the rectifier, charger, inverter and static switch while continuing to supply the load from the bypass AC source. It shall be possible to send to the UPS an external EPO order resulting in opening of the battery circuit breaker and the upstream circuit breaker. 7 - Environment conditions 7.1 - UPS (not including battery) 7.1.1 - Operation The UPS, not including the battery, shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: 0° C to +40° C. ● recommended temperature range: +20° C to + 25° C; ● maximum temperatures: 40 °C for 8 hours ● maximum relative humidity: 95% at 25° C; ● maximum altitude without power derating: 1000 meters. 7.1.2 - Storage The UPS, not including the battery, shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.7 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 8 - Protection 8.1 - UPS The UPS shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2 - Rectifier and charger The rectifier and charger shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer or if the temperature exceeds the limits specified above. 8.3 - Inverter Inverters shall self-protect against overloads and short-circuits, irrespective of the operating mode (AC power or battery power). 8.4 - Batteries 8.4.1 - Protection against deep discharge and self-discharge The UPS shall comprise a device designed to protect the battery against deep discharges, taking into account the characteristics of the discharge cycles, with isolation of the battery by a circuit breaker. 8.4.2 - Independent regulation and monitoring systems A regulation system shall regulate the battery voltage and the charge current. A second system, independent of the regulation, shall monitor the battery voltage and the charge current. Consequently, if the regulation system fails, the monitoring system steps in to shut down the charger and avoid overcharging. 8.4.3 - Regulation of the battery voltage depending on the ambient temperature A temperature sensor adapts the charge voltage to the ambient temperature. This regulation system takes into account the chemical reaction and prolongs the battery service life. The permissible temperature range is set in the personalisation parameters. An alarm shall be issued for temperatures outside the permissible range. 9 - Battery management As the life of the batteries is very sensitive to operating conditions, the battery shall be managed in an optimum manner. In addition to the devices indicated in section 8.4 "Batteries", the battery-management system shall include the features listed below. 9.1 - Self-test The battery shall include a self-test system initiated in two manners: ● as necessary by a manual command; ● automatically at user-defined intervals. This self-test system shall update the battery parameters and detect any abnormal deterioration to facilitate preventive maintenance. 9.2 - Measurement of actual backup time The battery function shall be combined with a system that continuously monitors the actual backup time available (AC source present) or remaining (AC source absent), according to the actual load on the UPS, the battery temperature and the age of the battery. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.8 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 9.3 - Digital battery monitoring The UPS shall be equipped with a system for battery digital management. Based on a number of parameters (percent load, temperature, battery type and age), the system shall control the battery charge voltage and continuously calculate: ● The true available backup time ● The remaining service life. 9.4 - Block by block monitoring To further optimise battery availability and service life, it shall be possible to equip the UPS with an optional system to continuously monitor all battery strings and display a block by block failure prediction. The system shall include the functions listed below. ● Continuous measurement of the voltage of each block. ● Continuous measurement of the internal resistance. ● Identification of faulty blocks (trend curves). ● Possibility of replacing individual blocks. ● Remoting of all information via Ethernet, dry contacts or JBus. 10 - User interface and communication 10.1 - User interface UPS operation shall be facilitated by a user interface comprising: ● a colour graphic display (touch screen); ● controls; ● status indications with mimic panel. 10.1.1 - Graphic display The graphic display shall facilitate operation by offering the functions listed below. ● animated colour mimic diagram The mimic diagram shall enable display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass). It can be used to supervise either a single UPS unit or a configuration with up to 6 UPS units connected in parallel and a centralized-bypass cabinet. ● display of measurements It shall be possible to display the following measurements: - inverter output phase-to-phase voltages; - inverter output currents; - inverter output frequency; - voltage across battery terminals; - battery charge or discharge current; - rectifier/charger input phase-to-phase voltages; - rectifier/charger input currents; - crest factor; - active and apparent power; - power factor of the load; - battery temperature. ● display of status conditions and events It shall be possible to display the following indications: - load on battery power; - load on UPS; - load on automatic bypass; - general alarm; - battery fault; - remaining battery backup time; - low battery warning; - bypass AC source outside tolerances; - battery temperature. Additional information shall be provided in view of accelerating servicing of the system, as specified in section 11 “Maintainability”. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.9 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) ● display of operating graphs It shall be possible to display curves and bargraphs over significant periods for the measurements mentioned above. ● display of statistics: number of overloads, number of transfers to battery power, cumulative time on battery power, maximum power, demand power. ● log of time-stamped events This function shall store in memory and make available, for automatic or manually initiated recall, time-stamped logs of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. It shall be possible to time stamp and store at least 3 000 events. 10.1.2 - Controls The UPS shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of the UPS, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● EPO terminal block The UPS shall be equipped with an emergency power off terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of UPS units; - opening of the static switch on the bypass line and of the battery circuit breaker; - opening of an isolated dry contact on the programmable card. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. 10.1.3 - Status indications with mimic panel Indication of status conditions shall be distinct of the graphic display. Three LEDs on the control panel indicate the following status conditions: ● load protected; ● minor fault; ● major fault. The mimic panel shall represent the UPS and indicate the status of the load supply using five two-colour (red and green) LEDs: ● load supplied (LED at UPS output on mimic panel), ● inverter on (LED on inverter on mimic panel), ● operation on battery power (LED between battery and inverter on mimic panel), ● bypass activated (LED on bypass on mimic panel), ● PFC rectifier on (LED on rectifier on mimic panel). A buzzer shall warn the user of faults, malfunctions or operation on battery power. 10.2 - Communication 10.2.1 - Standard communication It shall be possible to remote the following controls, indications and measurements. To that end, the UPS shall have as standard equipment: ● a dry contact card 10.2.2 - Communications options The UPS shall be designed to enable the extension of communications, without system shutdown, to the following types of cards: ● an SNMP communication card for connection to an Ethernet network, for connection to a computer-network management system; ● an RS485 serial-link communication card capable of implementing the JBus/ModBus protocol for connection to a building management system (BMS); ● an RS232 serial-link communication card for communication with a modem and a remote-maintenance system; ● an XML-Web communication card for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser. The UPS shall be detectable by supervision software for large UPS systems. Shutdown and administration software shall be available in addition to the communication cards. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.10 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 11 - Maintainability For optimum safety during servicing, a maintenance bypass shall be available to completely isolate the UPS. 11.1 - Local and remote diagnostics and monitoring - E. Services ● The UPS shall be equipped with a self-test system to check operation of the system as a whole each time it is started. To that end, the supply control/monitoring electronics shall offer: ● auto-compensation of component drift; ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote); ● overall readiness for remote supervision services provided by the manufacturer. 12 - Standards and tests 12.1 - Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. ● IEC 6014A-4: UPS - Performance. ● IEC 62040-1 and EN 62040-1: UPS - Safety. ● IEC 62040-2 and EN 62040-2: UPS - Electromagnetic compatibility - [level C3 / C2 class A is optional]. ● IEC 62040-3 and EN 62040-3: UPS - Performance. ● IEC 60950 / EN 60950: Safety of IT equipment, including electrical business equipment. ● IEC 61000-2-2: Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. ● IEC 61000-4: EMC - Electrical fast transient/burst immunity. ● IEC 439: Low-voltage switchgear and controlgear assemblies. ● IEC 60529: Degrees of protection provided by enclosures (IP Code). ● ISO 3746: Sound power levels. ● CE marking. What is more, the equipment must comply with environmental-protection standards, with production taking place on premises certified ISO 14001. The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. 12.2 - Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). 13 - Test procedures and quality system 13.1 - Test procedures The UPS manufacturer shall provide proof of a stringent Quality Assurance programme. In particular, the main equipment manufacturing stages shall be sanctioned by appropriate tests such as: ● incoming components inspection, discrete subassembly testing; ● complete functional checks on the final product. Equipment shall undergo on-load burn-in before leaving the factory. Final inspection and adjustments shall be documented in a report drawn up by the supplier’s Quality Inspection department. ISO 9001 or 9002 certification of the production site is compulsory. 13.2 - Quality system The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.11 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 14 - Services 14.1 - Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 14.2 - Technical competency ● customer operators: the supplier shall offer a level 2 training program. ● service personnel: the supplier shall ensure that service personnel are qualified for level 4. 14.3 - Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorised agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). 14.4 - System start-up ● The system and equipment shall be started up on site by the supplier or its authorised agent. The procedure shall include checks on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. 14.5 - Replacement parts ● The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 14.6 Recycling and renovation/substitution ● At the end of the UPS service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 15 - Warranty The rectifier/charger and inverter subassemblies shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.12 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) 16 - Installation services Required services include: ● supply of the UPS and any accessory parts or elements; ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site; ● connections between the battery and the UPS; ● connection of the normal AC source to the rectifier/charger; ● connection of the bypass AC source to the input transformer or bypass input; ● connection of the load circuits to the UPS output. 17 - Electrical diagram Fig.: UPS electrical diagram. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.13 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) Appendix. Check list Type of UPS Total rated power (kVA) at PF 0.8 kVA Manufacturer Range of products Operating mode (IEC 62040-2) double conversion Parallel connection ≤ 4 integrated parallel units or 6 parallel units with SSC kVA max. yes no yes no Rectifiers Three-phase input voltage at Pn 380 or 400 or 415 V ± 10 % yes no Frequency 50 or 60 Hz ± 10 % yes no Sinusoidal input current THDI upstream ≤ 4 % with active filter yes no Input power factor PF > 0.95 with active filter yes no yes no No inrush or start-up current Rapid battery charger Backup time 10 minutes in t ≤ 11 hours, 45 minutes in t ≤ 24 hours yes no Voltage regulation ±1% yes no yes no yes no yes no Independent regulation/monitoring systems Battery Type standard sealed lead acid in a cabinet other Service life years yes no Backup time minutes yes no yes no yes no yes no Battery management and protection Temperature correction Measurement of actual backup time, depending on: load, temperature, age Cold start on battery power Protection against deep discharge with circuit-breaker opening yes no Charge-current limiting 0.05 C10 to 0.1 C10 (depending on the battery) yes no Self-tests yes no Calculation of real backup time yes no Block by block monitoring yes no Management of 2 independent circuit breakers yes no APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.14 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) Inverter Volts yes no ± 0.5 % yes no Steady-state conditions ± 2% yes no Voltage transients ± 5% (load from 0 to 100 or 100 to 0 %) yes no Output voltage distortion at Pn THDU < 3% yes no Unbalanced load conditions Voltage variations < 1.5 % yes no yes no ± 0.5 Hz yes no ± 0.25 Hz to 2 Hz yes non Frequency synchronisation with an external ± 8 % of rated frequency source yes no Overload capacity 125% In for 10 minutes yes no 150% In for 1 minute yes no Current limiting 212% In for 150 milliseconds yes no Crest factor up to 3:1 yes no yes no yes no yes no > 94% at Pn yes no selection of operating language yes no personalisation menu with password yes no display measurements, status, events, graphs yes no event log Time-stamping 3000 events yes no trend curves Power, voltage, currents and battery backup time values yes no statistics % time on batteries, number of transfers to batteries, average percent load yes no Controls ON, OFF, EPO terminal block yes no Status indications with mimic panel Audio alarm, LEDs yes no Three-phase output voltage with neutral adjustable Hz Output frequency Variation in output frequency adjustable Static bypass Static bypass Short-circuit withstand of static bypass depending on power Built-in maintenance bypass Efficiency Normal mode User interface Graphic display APC by Schneider Electric 05/2009 edition ch.6 - spec. 5a – p.15 Specification guide no. 5a Single UPS, three-phase, 800 to 900 kVA (cont.) Communication Dry contacts card yes no EPO terminal block yes no Options Ethernet SNMP card yes no RS485 JBus/ModBus card yes no RS232 U-Talk card yes no XML-Web card yes no Supervision software yes no with shutdown management yes no Certified standards and tests See list in section 12.1 yes no Certification of performance TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier Level 4 NFX 060-010 yes no Diagnostics and monitoring Remote yes no Technical support International yes no yes no Administration software Certification Services Operation, Maintainability Access to power components through front Access to communication through front hot-swap cards yes no Access to batteries through front hot-swap batteries yes no Around the world yes no Availability Availability of original replacement parts t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes yes no no Emergency services yes no Renovation / substitution programmes yes no Maintenance programmes APC by Schneider Electric Preventive Predictive 05/2009 edition ch.6 - spec. 5a – p.16 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA* * Maximum power rating without redundancy Contents 1 - UPS definition ....................................................................................................................................... 2 1.1 - Purpose ...................................................................................................................................... 2 1.2 - Brief description .......................................................................................................................... 2 2 - Operating principle ............................................................................................................................... 3 2.1 - Normal operation ........................................................................................................................ 3 2.2 - Operation on battery power ........................................................................................................ 3 2.3 - Battery recharge ......................................................................................................................... 3 2.4 - Parallel operation with redundancy ............................................................................................. 3 2.4 - Transfer to bypass AC source..................................................................................................... 3 2.5 - UPS maintenance ....................................................................................................................... 3 2.6 - Battery maintenance ................................................................................................................... 4 2.7 - Cold start (AC power absent) ...................................................................................................... 4 3 - Sizing and general characteristics ...................................................................................................... 4 3.1 - Technology ................................................................................................................................. 4 3.2 - Rating ......................................................................................................................................... 4 3.3 - Battery backup time .................................................................................................................... 4 3.4 - Types of loads accepted ............................................................................................................. 4 3.5 - Limitation of harmonics upstream of the UPS ............................................................................. 5 3.6 - Efficiency .................................................................................................................................... 5 3.7 - Noise level .................................................................................................................................. 5 4 - AC sources............................................................................................................................................ 5 4.1 - Normal AC source ...................................................................................................................... 5 4.2 - Bypass AC source ...................................................................................................................... 5 5 - Electrical characteristics...................................................................................................................... 5 5.1 - Rectifier and charger................................................................................................................... 5 5.2 - Batteries ..................................................................................................................................... 6 5.3 - Inverter ....................................................................................................................................... 6 5.4 - Static bypass .............................................................................................................................. 7 5.5 - Discrimination and short circuit capacity ..................................................................................... 7 5.6 - System earthing arrangement ..................................................................................................... 7 6 - Mechanical characteristics .................................................................................................................. 8 6.1 - Mechanical structure ................................................................................................................... 8 6.2 - Scalable design .......................................................................................................................... 8 6.3 - Dimensions ................................................................................................................................. 8 6.4 - Connections ................................................................................................................................ 8 6.5 - Ventilation ................................................................................................................................... 8 6.6 - Safety ......................................................................................................................................... 8 7 - Environment conditions ....................................................................................................................... 9 7.1 - UPS (not including battery) ......................................................................................................... 9 8 - Protection .............................................................................................................................................. 9 8.1 - UPS ............................................................................................................................................ 9 8.2 - Rectifier/chargers ........................................................................................................................ 9 8.3 - Inverters ...................................................................................................................................... 9 8.4 - Batteries ..................................................................................................................................... 9 9 - Battery management ............................................................................................................................ 10 9.1 – Self-test...................................................................................................................................... 10 9.2 - Measurement of actual backup time ........................................................................................... 10 9.3 - Digital battery management ........................................................................................................ 10 9.4 - Block by block monitoring ........................................................................................................... 10 10 - User interface and communication ................................................................................................... 10 10.1 - User interface ........................................................................................................................... 10 10.2 - Communication ......................................................................................................................... 11 11 - Maintainability..................................................................................................................................... 12 12 - Standards and tests .......................................................................................................................... 13 13 - Test procedures and quality system ................................................................................................ 13 14 - Services ............................................................................................................................................... 14 14.1 - Maintenance ............................................................................................................................. 14 14.2 - Technical competency .............................................................................................................. 14 14.3 - Functional components ............................................................................................................. 14 14.4 - System start-up......................................................................................................................... 14 14.5 - Replacement parts .................................................................................................................... 14 14.6 - Recycling and renovation .......................................................................................................... 14 15 - Warranty .............................................................................................................................................. 14 16 - Installation services ........................................................................................................................... 15 17 - Electrical diagram ............................................................................................................................... 15 Appendix. Check list.................................................................................................................................. 17 APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.1 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 1 - UPS definition 1.1 - Purpose The purpose of this specification is to define the design, manufacture and testing characteristics required in view of supplying, putting into operation and maintaining an Uninterruptible Power Supply (referred to as a UPS in the rest of this document). The UPS shall be designed to supply dependable electric power to: For information purposes Single-UPS unit with static bypass For n+1 redundancy with centralized bypass 2 UPS units 3 UPS units 4 UPS units 5 UPS units 6 UPS units MTBF in hours 475000 3.11x106 2.42x106 1.97 x106 1.67x106 1.44x106 Non availability 2.1x10-5 3.22x10-6 4.14x10-6 5.07 x10-6 6 x10-6 6.95 x10-6 1.2 - Brief description The UPS system shall be made up of …[ 2 / 3 / 4 / 5 / 6 ]…identical parallel-connected UPS units with the same power rating, operating in double-conversion mode (also called on-line mode) in accordance with the VFI category described in standard IEC 62040-2. Each UPS unit shall have a unit rating of …[ 800 / 900 ]… kVA, made up of the following components, described in this specification: ● rectifier; ● battery charger; ● inverter; ● battery; ● a battery-management system. In addition, the UPS shall be equipped with: ………………………………………………………………………………………………………………………….. ( for parallel connection of two single UPS units, with redundancy) ● static bypass (via a static switch) on each unit; ● manual maintenance bypass on each unit; ● user and communications interface on each unit. ………………………………………………………………………………………………………………………….. ( for parallel connection with an external maintenance-bypass cabinet, up to four units) ● static bypass (via a static switch) on each unit; ● common, external, maintenance bypass for all units, installed in a cabinet; ● user and communications interface on each unit. ………………………………………………………………………………………………………………………….. ( for parallel connection with a centralized-bypass cabinet, up to six units) ● a centralized bypass shall be made up of the following components: - static bypass (via a static switch); - manual maintenance bypass. The centralized bypass shall be sized to support the entire load. ● a user and communications interface for the entire UPS system. The UPS system shall also comprise any and all other devices required for safe operation and maintenance, including circuit breakers, switches, etc. The UPS system shall ensure continuity of electric power to the load within the specified tolerances, without interruption upon failure or deterioration of the normal AC source (utility power) for a maximum protection time determined by the capacity of the backup batteries installed. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.2 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 2 - Operating principle The double-conversion UPS (also called on-line) shall operate as defined below. 2.1 - Normal operation (normal AC source available) The rectifier supplies the inverter with DC current while the charger simultaneously float charges the battery. The load is continuously supplied with dependable electrical power by the inverter. ( for parallel connection with a centralized bypass cabinet, up to six units) A current-loop system shall ensure automatic distribution of the total load between the various parallel-connected units. 2.2 - Operation on battery power (normal AC source not available or outside tolerances) Upon failure or excessive deterioration of the normal AC source, the inverter shall continue to supply the load from battery power without interruption or disturbance, within the limits imposed by the specified battery backup time. 2.3 - Battery recharge (normal AC source restored) When the normal AC source is restored, the rectifier shall again power the inverter, without interruption or disturbance to the load, while the charger automatically recharges the battery. 2.4 - Parallel operation with redundancy …………………………………………………………………………………………………………………………………. ( without redundancy) The system shall not be redundant. The …[ 2 / 3 /4 / 5 / 6 ]… UPS units must operate in parallel to supply the load. Shutdown of one unit shall result in transfer to …[ the various static bypasses, connected to the same bypass AC source ] …[ the centralized bypass ] ………………………………………………………………………………………………………………………………….. ( with redundancy) The units shall operate in parallel and redundantly, with the load shared equally between the units. Redundancy shall be of the "n+1" (or n+2) type, i.e. "1" (or 2) units shall be redundant in the total of n units. If a major fault occurs on a unit, it shall automatically disconnect. If the remaining unit(s) are sufficient to supply the load, it/they shall remain in operation. If the total available power is insufficient, the load shall be automatically transferred, without interruption, to the bypass AC source, if it is within tolerances. ………………………………………………………………………………………………………………………………….. 2.5 - Transfer to bypass AC source In the event of an overload exceeding system capabilities or UPS shutdown, the static bypass switch shall instantaneously transfer the load to the bypass AC source without interruption, on the condition that bypass power is available and within tolerances. ………………………………………………………………………………………………………………………………….. ( for parallel connection with an external maintenance-bypass cabinet, up to four units) During transfer, the system shall simultaneously switch the static switches. ………………………………………………………………………………………………………………………………….. ( for parallel connection with a centralized-bypass cabinet, up to six units) Transfer shall be carried out by the common static bypass in the centralized-bypass cabinet, with simultaneous orders to the UPS units. …………………………………………………………………………………………………………………………………. Transfer of the load back to the UPS-unit output, synchronised with the bypass AC source, shall be automatic or manual. During transfer, the load shall not suffer an outage or disturbance in the supply of power. On request, the UPS system may automatically transfer the load with a micro-interruption if a major fault occurs on the UPS system and if synchronisation with the bypass source has not been established. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.3 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 2.6 - UPS maintenance For maintenance purposes, all electronic components shall be accessible from the front of the UPS. In addition, a manually operated mechanical bypass system shall be: ………………………………………………………………………………………………………………………………….. ( for a two-UPS system with active redundancy) - Built into each UPS unit ………………………………………………………………………………………………………………………………….. ( with external maintenance-bypass cabinet) - Installed separately in the external maintenance bypass cabinet ………………………………………………………………………………………………………………………………….. ( with centralized-bypass cabinet - Installed separately in the centralized bypass. ………………………………………………………………………………………………………………………………….. This system shall be designed to isolate the UPS while continuing to supply power to the load from the bypass AC source. The UPS shall also include a device making it possible to isolate the rectifiers and the chargers from the normal AC source. 2.7 - Battery maintenance For safe maintenance on the battery, the system shall include a circuit breaker to isolate the battery of each parallel-connected UPS unit from the rectifier, the corresponding charger and the inverter. When the battery is isolated from the system, the UPS shall continue to supply the load without interruption or disturbance, except in the event of a normal AC source outage. 2.8 - Cold start (normal AC source absent) The battery of each unit shall be capable of ensuring UPS start-up even if normal AC power is not available and continuing operation within the specified back-up time (start on battery power shall be possible on the condition that the system was already started with AC power present). 3 - Sizing and general characteristics 3.1 - Technology Each unit in the UPS system shall be based on IGBT technology with built-in thermal monitoring and a freefrequency chopping mode to dynamically optimise efficiency and power quality. 3.2 - Rating The UPS system shall be sized to continuously supply a load of kVA, at a power factor (pf) of [ 0.8 / 0.9 ]. It shall be made up of ...[2 / 3 / 4 / 5 / 6]... UPS units, each with an identical rating of ...[ 800 / 900]... kVA. The total installed power rating shall thus be kVA. ...[Consequently, 1 (or 2) unit(s) may be redundant.] 3.3 - Battery backup time The battery backup time in the event of a normal AC source outage shall be _______ minutes, for a load power factor of 0.8. Battery service life shall be equal to at least …[ 10 / 12 ]…years. It shall be selected and sized correspondingly, for a load power factor of 0.8. 3.4 - Types of loads accepted The UPS shall accept high crest factors (3:1) without derating to ensure correct operation with computer loads. The total harmonic voltage distortion at UPS output (THDU downstream) shall respect the following limits: ● THDU downstream ph/ph ≤ 3 % and ph/N ≤ 4% for linear loads. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.4 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 3.5 - Limitation of harmonics upstream of the UPS The UPS system shall not draw a level of harmonic currents that could disturb the upstream AC system, i.e. it shall comply with the stipulations of guide IEC 61000-3-4. To that end, it shall be possible to equip each rectifier/charger input with a filter of the type …[compensated LC / non-compensated LC / with contactor / double-bridge / phase shifting]... capable of limiting the total harmonic distortion of the current (THDI) upstream to < 7%. If necessary, it shall be possible to use an electronic active filtering system to obtain, at the normal AC input, the following levels, constant from 50% to 100% load: ● total harmonic current distortion (THDI) upstream of the rectifier/charger not exceeding 4%; ● input power factor (pf) greater than 0.95. 3.6 - Efficiency Overall efficiency shall be greater than or equal to: ● 93% at full rated load (In); ● 94% at half rated load (In/2). 3.7 - Noise level The noise level for each unit, measured as per standard ISO 3746, shall be less than 72 dBA. 4 - AC sources The UPS shall be designed to receive power from the sources listed below. 4.1 - Normal AC source (rectifier input) The normal AC source supplying the UPS shall, under normal operating conditions, have the following characteristics: ● rated voltage: 380 - 400 or 415 volts rms at full rated load Pn; ● number of phases: 3 ; ● frequency: Hz ± 10%. 4.2 - Bypass AC source (static-bypass input, if separate from rectifier input) The bypass power supplying the UPS in the event of an inverter shutdown (maintenance, failure) or an overload (short-circuit, heavy inrush currents, etc.) shall have the following characteristics: ● voltage: / volts, ± 10%; ● number of phases: 3 + N + earth; (a non-distributed neutral is possible); ● frequency: Hz ± 5% (adjustable up to ± 2 Hz). Outside these tolerances, it shall be possible to supply the load, but in downgraded mode. 5 - Electrical characteristics 5.1 - Rectifier and charger 5.1.1 - Supply Each rectifier and charger module shall be supplied via the normal AC input (see § 4. AC sources) and shall have the characteristics presented below. 5.1.2 - Inrush current A device shall be provided to limit inrush currents. When AC power fails and during genset start, the rectifier shall gradually limit the power it draws over a 10-second walk-in ramp. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.5 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 5.1.3 - Battery-current limiting For long battery life, an electronic device shall automatically limit the charging current to the maximum value specified by the battery supplier (0.1 x C10 for a sealed lead-acid battery). 5.1.4 - Operating mode The charger of each UPS unit shall be sized to recharge the battery rapidly: a battery with a backup time of…[5 / 10 ]… minutes in less than 11 hours] (following a discharge to Pn/2 to recover 90% of backup time). 5.1.5 - Input power factor The required level of performance is indicated in section 3.5 "Limitation of harmonics upstream of the UPS". 5.1.6 - Voltage regulation Rectifier/charger regulation shall take into account the ambient temperature of the battery and shall ensure DC output voltage fluctuations of less than 1% irrespective of load and AC input voltage variations (within the limits specified in section 4.1 “Normal AC source”). 5.2 - Batteries Each UPS unit shall be equipped with its own battery of the …[sealed lead-acid type, factory mounted and wired in a cabinet identical to that of the UPS,] … [sealed lead-acid type, mounted on shelves,]…[vented lead-acid type, mounted on a rack,]... with a service life equal to at least …[10 / 12]… years. Each battery shall be sized to ensure continuity in the supply of power to the corresponding inverter for at least …[8 / 10 / 15 / 30 …]… minutes, in the event of a normal AC source failure, with the inverter operating at full rated load, i.e. kVA at a power factor (pf) of 0.8. Sizing calculations shall assume an ambient temperature between 0° C and 35° C The UPS shall include devices to ensure: ● effective battery protection (see section 8.4 "Protection - Battery"); ● battery management (see section 9 "Battery management"). 5.3 - Inverter Each inverter shall be sized to supply a rated load of …[ 800 / 900 ]… kVA at [ 0.8 / 0.9 ] pf and shall satisfy the specifications listed below. 5.3.1 - Output voltage ● Rated voltage …[ 380 / 400 / 415 ]… volts rms, adjustable via the user interface (see section 10), within tolerances of +/- 0.5%. ● Number of phases 3 phases + neutral + earth. ● Steady-state conditions The variation in the rated voltage shall be limited to ± 2% for a balanced load between 0 and 100% of the rated power, irrespective of normal AC input and DC voltage levels, within the limits specified in section 4.1 “Normal AC source” and 5.1.4 “Rectifier/charger - Operating modes and DC-voltage levels”. ● Voltage variations for load step changes Output voltage transients shall not exceed ± 0.5% of rated voltage for 0 to 100% or 100 to 0% step loads. In all cases, the voltage shall return to within steady-state tolerances in less than 100 milliseconds. ● Unbalanced load conditions For a load unbalance between phases, the output voltage variation shall be less than 1.5%. 5.3.2 - Output frequency ● Rated frequency - 50 or 60 Hz. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.6 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 5.3.3 - Synchronisation with bypass power ● When bypass power is within tolerances To enable transfer to bypass power (see conditions below in section 5.4 "Static-bypass"), the inverter output voltage shall be synchronised with the bypass source voltage whenever possible. To that end, during normal operation, a synchronisation system shall automatically limit the phase deviation between the voltages to 3 degrees, if the bypass source frequency is sufficiently stable (within adjustable tolerances of ± 0.5 Hz with respect to the rated frequency). ● Synchronisation with an external source It shall be possible to synchronise with all types of external source. ● Autonomous operation following loss of synchronisation with bypass power When the bypass source frequency deviates beyond these limits, the inverter shall switch over to free-running mode with internal synchronisation, regulating its own frequency to within ± 0.02 Hz. When bypass power returns to within tolerances, the inverter shall automatically resynchronise. ● Variation in frequency per unit time To avoid transmitting to the inverter any excessive frequency variations on the bypass AC source when it is within tolerances, inverter frequency variations per unit time (dF/dt) shall be limited to 1 Hz/s or 2 Hz/s (user defined). 5.3.4 - Overload capacity The UPS shall be capable of supplying for at least: ● 1 minutes a load representing 150% of the rated load. If necessary, the UPS shall operate as a generator (current limiting) with a peak capacity of 212% for 150 milliseconds, to allow highly disturbed transient operating states (high overloads, very high crest factors, etc.) without transferring the load to the bypass. 5.4 - Static bypass 5.4.1 - Load transfer to the static bypass Instantaneous transfer of the load from the inverters to bypass power and back shall take place without a break or disturbance in the supply of power to the load, on the condition that the bypass source voltage and frequency are within the tolerances specified in section 4.1 "Bypass AC source" and that the inverters are synchronized. Transfer shall take place automatically in the event of a major overload or an internal UPS-system fault. Manually initiated transfer shall also be possible. If the bypass power is outside the specified tolerances or is not synchronized with the inverters, automatic transfer of the load from the inverters to bypass power shall be inhibited or shall take place after a calibrated interruption of 500 to 800 milliseconds. Manual initiation of this transfer as well as transfer back to the inverters shall also be possible. 5.4.2 - Static-switch protection The static switch ..................................................................................................................................................................... ( with centralized-bypass cabinet) common centralized-bypass ..................................................................................................................................................................... ( other cases) in each UPS unit ..................................................................................................................................................................... shall be equipped with an RC filter for protection against switching overvoltages and lightning strikes. 5.5 - Discrimination and short-circuit capacity If the bypass power is within the tolerances specified in section 4.2 "Bypass AC source" section, the presence of the static switch ..................................................................................................................................................................... ( with centralized-bypass cabinet) common centralized-bypass ..................................................................................................................................................................... ( other cases) in each UPS unit, supplied by the same bypass AC source ..................................................................................................................................................................... shall make it possible to use the short-circuit power of the bypass source to trip the downstream protection devices of the inverter. To ensure tripping in a selective manner, the available power shall be sufficient to trip protection devices with high ratings (circuit breaker rated In/2 or UR fuses rated In/4, where In is the rated inverter current). If the bypass source is outside the specified tolerances, the inverter on its own shall, for the same discrimination requirements, be capable of tripping circuit breakers rated In/2 or UR fuses rated In/4, irrespective of the type of short-circuit. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.7 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 5.6 - System earthing arrangement The UPS shall be compatible with the following system earthing arrangements: ● upstream source: …[ TT/ IT / TNS / TNC ]… ● downstream installation: …[ TT/ IT / TNS / TNC ]… If the upstream and downstream earthing arrangements are different, galvanic isolation shall be provided on the static-bypass line. 6 - Mechanical characteristics 6.1 - Mechanical structure UPSs and batteries shall be installed in cabinet(s) with a degree of protection IP20 (standard IEC 60529). Access to the subassemblies making up the system shall be exclusively through the front. 6.2 - Scalable design The UPS system shall be designed to allow the installed power to be easily increased on site by connection of additional UPS units, either to meet new load requirements or to enhance system availability by introducing redundancy. This transformation shall be possible directly on site, without returning the equipment to the factory and without causing excessive system downtime. 6.3 – Dimensions The UPS shall require as little floor space as possible. To gain space, it shall be possible to install the UPS with the back to the wall or back-to-back with another UPS. 6.4 - Connection To facilitate connections, all terminal blocks must be easily accessible from the front when the UPS is installed with the back to the wall. Entry of upstream and downstream power cables, as well as any auxiliary cables, shall be possible through the bottom for a false floor. The UPS shall be equipped with an earth-circuit connector, in compliance with the standards listed in section 13 "Standards and tests". The cables shall comply with the standards listed in section 12 "Standards and tests" and be mounted in compliance with the stipulations in section 6.6 "Safety". The neutral conductor shall be oversized for any third-order harmonic currents and their multiples (the size of the neutral shall be 1.5 times that of each phase). 6.5 - Ventilation The UPS units shall be provided with forced-air cooling. To facilitate positioning of UPS units (back to the wall), ventilation shall take place through the top with an air intake on the front. 6.6 - Safety For the safety of maintenance personnel, the cabinet shall be provided with a manually operated mechanical bypass designed to isolate the rectifier, charger, inverter and static switch while continuing to supply the load from the bypass AC source. It shall be possible to send to the UPS an external EPO order resulting in opening of the battery circuit breaker and the upstream circuit breaker. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.8 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 7 - Environment conditions 7.1 - UPS (not including battery) 7.1.1 - Operation The UPS, not including the battery, shall be capable of operating under the following environmental conditions without loss of performance: ● ambient temperature range: 0° C to +40° C. ● recommended temperature range: +20° C to + 25° C; ● maximum temperatures: 40 °C for 8 hours ● maximum relative humidity: 95% at 25° C; ● maximum altitude without power derating: 1000 meters. 7.1.2 - Storage The UPS, not including the battery, shall be designed for storage under the following conditions: ● ambient temperature range: -10° C to +45° C. 8 - Protection 8.1 - UPS Each UPS unit shall include protection against AC-source overvoltages (as per standard IEC 60146), excessive external or internal temperature rise and vibrations and impacts during transport. 8.2 - Rectifier and charger Each rectifier/charger shall be equipped to receive an external order to automatically shut down under the following circumstances: ● emergency off; in this case, the shutdown will be accompanied by opening of the battery circuit breaker; ● battery room ventilation fault. The rectifier and the charger shall automatically shut down if the DC voltage reaches the maximum value specified by the battery manufacturer. 8.3 - Inverter The load shall be protected against any overvoltages that could result from voltage regulation failure at the output of the inverters. The inverter (and the corresponding rectifier/charger) shall automatically shut down if the DC voltage reaches the minimum value specified by the battery manufacturer. Each inverter shall be equipped with an automatic shutdown system to protect its power circuits against overloads exceeding UPS-system overload capacity when bypass power is not available. In particular, a short-circuit on the load shall initiate a static shutdown of each inverter, without blowing a fuse. 8.4 - Batteries 8.4.1 - Protection against deep discharge and self-discharge The UPS shall comprise a device designed to protect the battery against deep discharges, taking into account the characteristics of the discharge cycles, with isolation of the battery by a circuit breaker. 8.4.2 - Independent regulation and monitoring systems A regulation system shall regulate the battery voltage and the charge current. A second system, independent of the regulation, shall monitor the battery voltage and the charge current. Consequently, if the regulation system fails, the monitoring system steps in to shut down the charger and avoid overcharging. 8.4.3 - Regulation of the battery voltage depending on the ambient temperature A temperature sensor adapts the charge voltage to the ambient temperature. This regulation system takes into account the chemical reaction and prolongs the battery service life. The permissible temperature range is set in the personalisation parameters. An alarm shall be issued for temperatures outside the permissible range. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.9 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 9 - Battery management As the life of the batteries is very sensitive to operating conditions, the battery shall be managed in an optimum manner. In addition to the devices indicated in section 8.4 "Batteries", the battery-management system shall include the features listed below. 9.1 - Self-test The battery shall include a self-test system initiated in two manners: ● as necessary by a manual command; ● automatically at user-defined intervals. This self-test system shall update the battery parameters and detect any abnormal deterioration to facilitate preventive maintenance. 9.2 - Measurement of actual backup time The battery function shall be combined with a system that continuously monitors the actual backup time available (AC source present) or remaining (AC source absent), according to the actual load on the UPS, the battery temperature and the age of the battery. 9.3 - Digital battery monitoring Each UPS shall be equipped with a system for battery digital management. Based on a number of parameters (percent load, temperature, battery type and age), the system shall control the battery charge voltage and continuously calculate: ● The true available backup time ● The remaining service life. 9.4 - Block by block monitoring To further optimise battery availability and service life, it shall be possible to equip each UPS with an optional system to continuously monitor all battery strings and display a block by block failure prediction. The system shall include the functions listed below. ● Continuous measurement of the voltage of each block. ● Continuous measurement of the internal resistance. ● Identification of faulty blocks (trend curves). ● Possibility of replacing individual blocks. ● Remoting of all information via Ethernet, dry contacts or JBus. 10 - User interface and communication 10.1 - User interface UPS operation shall be facilitated by a user interface comprising: ● a colour graphic display (touch screen); ● controls; ● status indications with mimic panel. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.10 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 10.1.1 - Graphic display The graphic display shall facilitate operation by offering the functions listed below. ● animated colour mimic diagram The mimic diagram shall enable display of installation parameters, configuration, operating status and alarms and indication of operator instructions for switching operations (e.g. bypass). It can be used to supervise either a single UPS unit or a configuration with up to 6 UPS units connected in parallel and a centralized-bypass cabinet. ● display of measurements It shall be possible to display the following measurements: - inverter output phase-to-phase voltages; - inverter output currents; - inverter output frequency; - voltage across battery terminals; - battery charge or discharge current; - rectifier/charger input phase-to-phase voltages; - rectifier/charger input currents; - crest factor; - active and apparent power; - power factor of the load; - battery temperature. ● display of status conditions and events It shall be possible to display the following indications: - load on battery power; - load on UPS; - load on automatic bypass; - general alarm; - battery fault; - remaining battery backup time; - low battery warning; - bypass AC source outside tolerances; - battery temperature. Additional information shall be provided in view of accelerating servicing of the system, as specified in section 11 “Maintainability”. ● display of operating graphs It shall be possible to display on the screen curves and bargraphs over significant periods for the measurements mentioned above. ● display of statistics: number of overloads, number of transfers to battery power, cumulative time on battery power, maximum power, demand power. ● log of time-stamped events This function shall store in memory and make available, for automatic or manually initiated recall, time-stamped logs of all important status changes, faults and malfunctions, complete with an analysis and display of troubleshooting procedures. It shall be possible to time stamp and store at least 3 000 events. 10.1.2 - Controls The UPS shall comprise the following controls: ● two ON and OFF buttons Located on the front panel of the UPS, they shall control UPS-unit ON/OFF status. It shall be possible to turn OFF the UPS externally via an isolated dry contact. ● EPO terminal block The UPS shall be equipped with an emergency power off terminal block for complete system shutdown following reception of an external control signal. The EPO command shall result in: - shutdown of UPS units; - opening of the static switch on the bypass line and of the battery circuit breaker; - opening of an isolated dry contact on the programmable card. ● alarm reset button This button shall turn off audio alarms (buzzer) (see section 10.1.3). If a new alarm is detected after clearing the first, the buzzer sounds again. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.11 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 10.1.3 - Status indications with mimic panel Indication of status conditions shall be distinct of the graphic display. Three LEDs on the control panel indicate the following status conditions: ● load protected; ● minor fault; ● major fault. The mimic panel shall represent the UPS and indicate the status of the load supply using five two-colour (red and green) LEDs: ● load supplied (LED at UPS output on mimic panel), ● inverter on (LED on inverter on mimic panel), ● operation on battery power (LED between battery and inverter on mimic panel), ● bypass activated (LED on bypass on mimic panel), ● PFC rectifier on (LED on rectifier on mimic panel). A buzzer shall warn the user of faults, malfunctions or operation on battery power. 10.2 - Communication 10.2.1 - Standard communication It shall be possible to remote the following controls, indications and measurements. To that end, each UPS shall have as standard equipment: ● a dry contacts card 10.2.2 - Communications options Each UPS shall be designed to enable the extension of communications, without system shutdown, to the following types of cards: ● an SNMP communication card for connection to an Ethernet network, for connection to a computer-network management system; ● an RS485 serial-link communication card capable of implementing the JBus/ModBus protocol for connection to a building management system (BMS); ● an RS232 serial-link communication card for communication with a modem and a remote-maintenance system; ● an USB communication card; ● an XML-Web communication card for direct UPS connection to an intranet network, without connection to a server, capable of supplying information via a standard web browser. The UPS shall be detectable by supervision software for large UPS systems. Shutdown and administration software shall be available in addition to the communication cards. 11 - Maintainability For optimum safety during servicing, a maintenance bypass shall be available to completely isolate the UPS. 11.1 - Local and remote diagnostics and monitoring - E. Services The UPS shall be equipped with a self-test system to check operation of the system as a whole each time it is started. To that end, the supply control/monitoring electronics shall offer: ● auto-compensation of component drift; ● acquisition of information vital for computer-aided diagnostics or monitoring (local or remote); ● overall readiness for remote supervision services provided by the manufacturer. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.12 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 12 - Standards and tests 12.1 - Standards All equipment shall be designed and built in accordance with accepted engineering practice and applicable international standards, in particular the standards listed below. ● IEC 6014A-4: UPS - Performance. ● IEC 62040-1 and EN 62040-1: UPS - Safety. ● IEC 62040-2 and EN 62040-2: UPS - Electromagnetic compatibility - [level C3 / C2 class A is optional]. ● IEC 62040-3 and EN 62040-3: UPS - Performance. ● IEC 60950 / EN 60950: Safety of IT equipment, including electrical business equipment. ● IEC 61000-2-2: Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. ● IEC 61000-4: EMC - Electrical fast transient/burst immunity. ● IEC 439: Low-voltage switchgear and controlgear assemblies. ● IEC 60529: Degrees of protection provided by enclosures (IP Code). ● ISO 3746: Sound power levels. ● CE marking. What is more, the equipment must comply with environmental-protection standards, with production taking place on premises certified ISO 14001. The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. 12.2 - Certification of conformity The manufacturer shall provide, on request, a complete qualification file demonstrating compliance with the above standards. What is more, the indicated levels of performance shall be confirmed by certification from independent laboratories (e.g. TÜV or Veritas). 13 - Test procedures and quality system 13.1 - Test procedures The UPS manufacturer shall provide proof of a stringent Quality Assurance programme. In particular, the main equipment manufacturing stages shall be sanctioned by appropriate tests such as: ● incoming components inspection, discrete subassembly testing; ● complete functional checks on the final product. Equipment shall undergo on-load burn-in before leaving the factory. Final inspection and adjustments shall be documented in a report drawn up by the supplier’s Quality Inspection department. ISO 9001 or 9002 certification of the production site is compulsory. 13.2 - Quality system The UPS design procedure shall be covered by an ISO 9001 quality system as well as a dependability study to ensure maximum reliability. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.13 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 14 - Services 14.1 - Maintenance The supplier shall propose contracts covering four levels of maintenance. ● Level one: simple checks and settings, procedures accessible without any dismounting and involving no risk. ● Level two: preventive maintenance, checks not inhibiting continuous operation of the system and preparing operators for Manufacturer services. ● Level three: trouble-shooting. Repairs by standard exchange of subassemblies and functional power and control components. Preventive-maintenance operations, both systematic and when indicated by qualified diagnosis. ● Level four: major preventive and corrective maintenance operations or technical upgrades during start-up, operation or renovation of the UPS installation and recycling of equipment or components representing a risk. These operations require the use of devices and means that have been calibrated by certified organisations. 14.2 - Technical competency ● customer operators: the supplier shall offer a level 2 training program. ● service personnel: the supplier shall ensure that service personnel are qualified for level 4. 14.3 - Functional components - organisation of supplier services ● Sufficient geographical proximity of the supplier or an authorised agent shall ensure reasonable access times to the customer site in view of reducing the mean time to repair (MTTR). The supplier shall be in a position to offer a contract limiting the response time to four hours. ● The supplier's logistics system and the availability 24 hours a day of original replacement parts shall similarly contribute to reducing to the greatest extent possible the mean time to repair (MTTR). 14.4 - System start-up ● The system and equipment shall be started up on site by the supplier or its authorised agent. The procedure shall include checks on the characteristics of the upstream and downstream protection devices and on the UPS installation parameters. 14.5 - Replacement parts ● The suppler shall undertake to provide certified original replacement parts for at least ten years following the date of delivery. 14.6 Recycling and renovation/substitution ● At the end of the UPS service life, the supplier shall guarantee the continuity of service of the customer's installations if necessary, including dismantling of equipment and replacement of equipment, in compliance with applicable standards on environmental protection. 15 - Warranty The rectifier/charger and inverter subassemblies shall be guaranteed (parts and labour on site) for one year following the start-up date. The sealed lead-acid battery shall be covered by the same warranty as the UPS. APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.14 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) 16 - Installation services Required services include: ● supply of the UPS and any accessory parts or elements; ● carriage-paid UPS transportation and delivery to the site. Options: ● UPS handling and installation on the site; ● connections between the battery and the UPS; ● connection of the normal AC source to the rectifier/charger; ● connection of the bypass AC source to the input transformer or bypass input; ● connection of the load circuits to the UPS output. 17 - Electrical diagram Fig. Two parallel-connected UPS units, with or without redundancy. Bypass AC input External bypass cabinet Normal AC input UPS1 P1 (kVA) Normal AC input Normal AC input UPS2 UPS3 P1 (kVA) P1 (kVA) Load Fig. UPS system with common, external bypass (up to four units). APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.15 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) Normal AC input Normal AC input Normal AC input Bypass AC input Centralized bypass Load Fig. UPS system with centralized bypass (up to six units). APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.16 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) Appendix. Check list Type of UPS Total rated power (kVA) at PF 0.8 kVA Manufacturer Range of products Operating mode (IEC 62040-2) double conversion Parallel connection ≤ 4 integrated parallel units or 6 parallel units with SSC kVA max. yes no yes no Rectifiers Three-phase input voltage at Pn 380 or 400 or 415 V ± 10 % yes no Frequency 50 or 60 Hz ± 10 % yes no Sinusoidal input current THDI upstream ≤ 4 % with active filter yes no Input power factor PF > 0.95 with active filter yes no yes no No inrush or start-up current Rapid battery charger Backup time 10 minutes in t ≤ 11 hours, 45 minutes in t ≤ 24 hours yes no Voltage regulation ±1% yes no yes no yes no yes no Independent regulation/monitoring systems Battery Type standard sealed lead acid in a cabinet other Service life years yes no Backup time minutes yes no yes no yes no yes no Battery management and protection Temperature correction Measurement of actual backup time, depending on: load, temperature, age Cold start on battery power Protection against deep discharge with circuit-breaker opening yes no Charge-current limiting 0.05 C10 to 0.1 C10 (depending on the battery) yes no Self-tests yes no Calculation of real backup time yes no Block by block monitoring yes no Management of 2 independent circuit breakers yes no APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.17 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) Inverter Volts yes no ± 0.5 % yes no Steady-state conditions ± 2% yes no Voltage transients ± 5% (load from 0 to 100 or 100 to 0 %) yes no Output voltage distortion at Pn THDU < 3% yes no Unbalanced load conditions Voltage variations < 1.5 % yes no yes no ± 0.5 Hz yes no ± 0.25 Hz to 2 Hz yes non Frequency synchronisation with an external ± 8 % of rated frequency source yes no Overload capacity 125% In for 10 minutes yes no 150% In for 1 minute yes no Current limiting 212% In for 150 milliseconds yes no Crest factor up to 3:1 yes no yes no yes no yes no > 94% at Pn yes no selection of operating language yes no personalisation menu with password yes no display measurements, status, events, graphs yes no event log Time-stamping 3000 events yes no trend curves Power, voltage, currents and battery backup time values yes no statistics % time on batteries, number of transfers o batteries, average percent load yes no Controls ON, OFF, EPO terminal block yes no Status indications with mimic panel Audio alarm, LEDs yes no Three-phase output voltage with neutral adjustable Hz Output frequency Variation in output frequency adjustable Static bypass Static bypass Short-circuit withstand of static bypass depending on power Built-in maintenance bypass Efficiency Normal mode User interface Graphic display APC by Schneider Electric 05/2009 edition ch.6 - spec. 5b – p.18 Specification guide no. 5b Parallel UPS, three-phase, 800/900 to 4800/5400 kVA (cont.) Communication Dry contacts card yes no EPO terminal block yes no Options Ethernet SNMP card yes no RS485 JBus/ModBus card yes no RS232 U-Talk card yes no XML-Web card yes no Supervision software yes no with shutdown management yes no Certified standards and tests See list in section 12.1 yes no Certification of performance TÜV yes no Quality certification ISO 9001 / 9002 yes no Eco-design and manufacturing ISO 14001 site yes no Technical competency of supplier Level 4 NFX 060-010 yes no Diagnostics and monitoring Remote yes no Technical support International yes no yes no Administration software Certification Services Operation, Maintainability Access to power components through front Access to communication through front hot-swap cards yes no Access to batteries through front hot-swap batteries yes no Around the world yes no Availability Availability of original replacement parts t < 4h 4<t<8 8<t<24 t>24 h Response time of Service teams yes yes no no Emergency services yes no Renovation / substitution programmes yes no Maintenance programmes APC by Schneider Electric Preventive Predictive 05/2009 edition ch.6 - spec. 5b – p.19 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy PART 1 - GENERAL 1.1 1.2 SUMMARY A. This specification describes the operation and functionality of a continuous duty, three-phase, solidstate, static Uninterruptible Power System (UPS) hereafter referred to as the UPS. The UPS shall utilize a rack-mounted redundant, scalable array architecture. The system power train shall be comprised of hot swappable / user replaceable 16kVA/16kW power modules, which shall operate in parallel. Each 16kVA/16kW power module contains a full rated input rectifier / boost converter (hereafter referred to as Input Converter), full rated output inverter, and battery charging circuit. The system shall also comprise of a user-replaceable continuous duty hot swappable bypass static switch module, hot swappable / user replaceable battery modules, redundant control modules, redundant logic power supplies, and LCD interface display. All of the above system components are housed in a standard, 600mm wide, 1070mm deep, 2000mm high equipment rack. B. In addition, this specification describes the performance, functionality, and design of the Maintenance Bypass, Power Distribution, Battery System, and connectivity solutions. C. The UPS and associated equipment shall operate in conjunction with a primary power supply and an output distribution system to provide quality uninterrupted power for mission critical, electronic equipment load. D. All programming and miscellaneous components for a fully operational system as described in this specification shall be available as part of the UPS. STANDARDS A. Safety: 1. IEC 60950-1 / EN 60950-1 Information technology equipment - Safety - Part: General requirements 2. IEC 62040-1/ EN 62040-1 Uninterruptible power systems (UPS) - General and safety requirements for UPS. 3. IEC 62040-3 / EN 1000-3 Uninterruptible power systems (UPS) - Method of specifying the test and performance requirements. 4. IEC 60439 Low-voltage switchgear and controlgear assemblies. 5. LV directive: 2006/95/EC B. Harmonics: 1. IEC 61000-2-2 / EN 61000-2-2 Compatibility levels for low-frequency conducted disturbances and signalling in public lowvoltage power supply systems. 2. IEC 61000-3-2 / EN 61000-3-2 Limits for harmonic current emissions (equipment input current ≤ 16 A/ph). 3. IEC 61000-3-4 / EN 61000-3-4 Limits for harmonic current emissions (equipment input current > 16 A/ph). 4. IEC 61000-3-5 / EN 61000-3-5 Limitation of voltage fluctuations and flicker. 5. EN 50160 Voltage characteristics of public networks. 6. IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems. C. EMC: 1. EN 50091-2 UPS - EMC. APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 1 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy 2. IEC 62040-2/ EN 62040-2 Uninterruptible power systems (UPS) - Electromagnetic compatibility (EMC) requirements. 3. EMC Directive 2004/108/EC For equipment liable to cause or be affected by electromagnetic disturbances. 1.3 1.4 D. Quality: 1. Design , production and servicing in compliance with standard ISO 9001 - quality organisation. E. Ecological environment: 1. Manufacturing in compliance with standard ISO 14001. F. Acoustic noise 1. ISO 3746 Sound power levels. 2. ISO 7779 / EN 27779 Measurement of airborne noise emitted by computer and business equipment. MODES OF OPERATION A. Normal: The input converter and output inverter shall operate in an on-line manner to continuously regulate power to the critical load. The input and output converters shall be capable of full battery recharge while simultaneously providing regulated power to the load for all line and load conditions within the range of the UPS specifications. B. Battery: Upon failure of the AC input source, the critical load shall continue being supplied by the output inverter, which shall derive its power from the battery system. There shall be no interruption in power to the critical load during both transfers to battery operation and retransfers from battery to normal operation. C. Recharge: Upon restoration of the AC input source, the input converter and output inverter shall simultaneously recharge the battery and provide regulated power to the critical load. D. Static Bypass: The static bypass shall be used to provide transfer of critical load from the Inverter output to the bypass source. This transfer, along with its retransfer, shall take place with no power interruption to the critical load. In the event of an emergency, this transfer shall be an automatic function. E. Maintenance Bypass: The system shall be equipped with an external make-before-break Maintenance Bypass to electrically isolate the UPS during routine maintenance and service of the UPS. The Maintenance Bypass shall completely isolate both the UPS input and output connections. SUBMITTALS A. Proposal Submittals: 1. 2. 3. 4. 5. 6. 7. B. As bid system bill of materials. Product catalog sheets or equipment brochures. Product guide specifications. System single-line operation diagram. Installation information, including weights and dimensions. Information about terminal locations for power and control connections. Drawings for requested optional accessories. Delivery Submittals: 1. Installation manual, which includes instructions for storage, handling, examination, preparation, installation, and start-up of UPS. 2. User manual, which includes operating instructions. APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 2 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy PART 2 – PRODUCT 2.1 2.2 DESIGN REQUIREMENTS A. The UPS shall be sized for _____ kVA and _____ kW load. B. The UPS battery shall be sized for _____ at a Power Factor of_____ for _____ minutes. SYSTEM CHARACTERISTICS A. System Capacity: The system shall be rated for full kW output in the following frame sizes 1. B. [48 / 160 ] kVA/kW - Can be configured with up to[ three / ten ]16kW power modules for N+0 Input: 1. AC Input Nominal Voltage: 380V, 400V or 415V with 3 Phase 4 wire, with ground 50/60Hz 2. AC Input Voltage Window: 200V - 477 V (If 100% load: 340V-477V providing charging to the battery system, depending on load system can be recharge from as low as 200V) 3. Short Circuit Withstand Rating: 30,000 Symmetrical Amperes with gG fuse in front of system 4. Maximum Frequency Range: 40-70Hz 5. Input Power Factor: a. > .99 at greater than 25% load 6. Input Current Distortion with no additional filters: a. < 5% at 100% load 7. Soft-Start: Shall be linear from 0-100% input current and shall not exhibit inrush. This shall take place over a 15 second time period C. UPS Output: 1. AC Output Nominal Output: 380V/400V/415V, 3 Phase 4 wire with ground, 50/60 Hz. + /- 1% For 100 % linear load 2. AC Output Voltage Regulation: + /- 3% for 100% non-linear load 3. Voltage Transient Response: +/- 5% maximum for 100% load step 4. Voltage Transient Recovery within <50 milliseconds 5. Output Voltage Harmonic Distortion: a. <2% THD maximum for a 100% linear load b. <6% THD maximum for a 100% non-linear load 6. Overload Rating: a. Normal Operation: 1) 150% for 60 seconds in normal operation 2) 125% for 10 minutes in normal operation 3) 150% for 60 seconds in battery operation b. Bypass Operation: 1) 150% for 60 seconds 2) 1000% for 100 milliseconds 7. System AC-AC Efficiency: >95% at 35 - 100% load 8. Output Power Factor Rating: For loads exhibiting a power factor of .5 leading to .5 lagging no derating of the UPS shall be required. 2.3 ENVIRONMENTAL A. Storage Ambient Temperature: -15°C to 40°C. APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 3 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy B. Operating Ambient Temperature: 0°C to 40°C. (25°C is ideal for most battery types). C. Relative Humidity: 0 to 95% Non-condensing Altitude: Maximum installation with no derating of the UPS output shall be 1000m above sea level. 1. 1500m – 95% load 2. 2000m – 91% load 3. 2500m – 86% load 4. 3000m – 82% load 2.4 INPUT POWER CONVERTER A. The input power converters of the system are housed within the parallel connected, removable power modules, and shall constantly control the power imported from the mains input of the system, to provide the necessary UPS power for precise regulation of the DC bus voltage, battery charging, and Main Inverter regulated output power. B. Input Current Total Harmonic Distortion: The input current THDI shall be held to 5% or less at full system, while providing conditioned power to the critical load bus, and charging the batteries under steady-state operating conditions. This shall be true while supporting loads of both a linear or nonlinear type. This shall be accomplished with no additional filters, magnetic devices, or other components. C. Soft-Start Operation: As a standard feature, the UPS shall contain soft-start functionality, capable of limiting the input current from 0-100% of the nominal input over a default 15 second period, when returning to the AC utility source from battery operation. The change in current over the change in time shall take place in a linear manner throughout the entire operation. (di/dt= constant) D. Magnetization Inrush Current: The UPS shall exhibit 0 inrush current as a standard product. If provided with an optional isolation transformer, inrush shall be limited to 6 times the nominal input current of the transformer. E. Input Current Limit: 1. The input converter shall control and limit the input current draw from utility to 150% of the UPS output. During conditions where input current limit is active, the UPS shall be able to support 100% load, charge batteries, and provide voltage regulation. 2. In cases where the source voltage to the UPS is nominal and the applied UPS load is equal to or less than 100% of UPS capacity, input current shall not exceed 125% of UPS output current, while importing necessary power for system losses. F. Charging: 1. The battery charging shall keep the DC bus float voltage of +/- 218v, +/-1% 2. The battery charging circuit shall contain a temperature compensation circuit, which will regulate the battery charging to optimize battery life. 3. The battery charging circuit shall remain active when in requested Static Bypass and in Normal Operation. G. 2.5 Back-feed Protection: The above-mentioned logic controlled contactor also provides the back-feed protection. OUTPUT INVERTER A. The UPS output inverter shall constantly recreate the UPS output voltage waveform by converting the DC bus voltage to AC voltage through a set of IGBT driven bi-directional power converters. In both normal operation and battery operation, the output inverters shall create an output voltage independent of the mains input voltage. Input voltage anomalies such as brown-outs, spikes, surges, sags, and outages shall not affect the amplitude or sinusoidal nature of the recreated output voltage sine wave of the output inverters. APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 4 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy 2.6 2.7 B. Overload Capability: The output power converters shall be capable of 1000% for short-circuit clearing. Steady-state overload conditions, of up to 150% of system capacity, shall be sustained by the inverter for 60 seconds in normal and battery operation. Should overloads persist past the outlined time limitation, the critical load will be switched to the automatic static bypass output of the UPS. C. Output Contactor: The output inverter shall be provided with an output mechanical contactor to provide physical isolation of the inverter from the critical bus. With this feature a failed inverter shall be removed from the critical bus. H. Battery Protection: The inverter shall be provided with monitoring and control circuits to limit the level of discharge on the battery system. I. Redundancy: The UPS shall be configured with redundant output inverters, each with semiconductor fusing, and logic controlled contactors to remove a failed component from the critical bus. STATIC BYPASS A. As part of the UPS, a system static bypass switch shall be provided. The system static bypass shall provide no break transfer of the critical load from the Inverter output to the static bypass input source during times where maintenance is required, or the inverter can not support the critical bus. Such times may be due to prolonged or severe overloads, or UPS failure. The UPS and static bypass switch shall constantly monitor the auxiliary contacts of their respective circuit breakers, as well as the bypass source voltage, and inhibit potentially unsuccessful transfers to static bypass from taking place. B. The design of the static switch power path shall consist of Silicon Controlled Rectifiers (SCR) with a continuous duty rating of 125% of the UPS output rating. C. Automatic Transfers: An automatic transfer of load to static bypass shall take place whenever the load on the critical bus exceeds the overload rating of the UPS. Automatic transfers of the critical load from static bypass back to normal operation shall take place when the overload condition is removed from the critical bus output of the system. Automatic transfers of load to static bypass shall also take place if for any reason the UPS cannot support the critical bus. D. Manual Transfers: Manually initiated transfers to and from static bypass shall be initiated through the UPS display interface. E. Overloads: The static bypass shall be rated and capable of handling overloads equal to or less than 125% of the rated system output continuously. For instantaneous overloads caused by inrush current from magnetic devices, or short circuit conditions, the static bypass shall be capable of sustaining overloads of 1000% of system capacity for periods of up to 100 milliseconds. F. Modular: The static bypass switch shall be of a modular design. G. System Protection: As a requirement, back-feed protection in the static bypass circuit shall also be incorporated in the system design. To achieve back-feed protection, a mechanical contactor in series with the bypass SCR(s) shall be controlled by the UPS/static switch, to open immediately upon sensing a condition where back-feeding of the static switch by any source connected to the critical output bus of the system is occurring. One such condition could be a result of a shorted SCR. DISPLAY AND CONTROLS A. Control Logic: The UPS shall be controlled by two fully redundant, user-replaceable / hotswappable control modules. These modules shall have separate, optically isolated, communication paths to the power and static switch modules. Logic power for the control modules shall be derived from redundant power supplies, each having a separate AC and DC input and output. The communication of the control modules shall be of Controller Area Network (CAN Bus). APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 5 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy B. Display Unit: A microprocessor controlled display unit shall be located on a hinged door in the front of the system. The display shall consist of an alphanumeric display with backlight, four LEDs for quick status overview, and a keypad consisting of pushbutton switches. C. Metered Data: The following metered data, shall be available on the alphanumeric display: 1. 2. 3. 4. 5. 6. D. Year, Month, Day, Hour, Minute, Second of occurring events Source Input Voltage Output AC voltage Output AC current Input Frequency Battery voltage Event log: The display unit shall allow the user to display a time and date stamped log of the most recent status and alarm events. E. Alarms: The display unit shall allow the user to display a log of all active alarms. The following minimum set of alarm conditions shall be available: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. APC by Schneider Electric Input Frequency outside configured range AC adequate for UPS but not for Bypass Low/No AC input, startup on battery Intelligence Module inserted Intelligence Module removed Redundant Intelligence Module inserted Redundant Intelligence Module removed Number of Batteries changed since last ON Number of Power Modules changed since last ON Number of Batteries increased Number of Batteries decreased Number of Power Modules increased Number of Power Modules decreased Number of External Battery Cabinets increased Number of External Battery Cabinets decreased Redundancy Restored Need Battery Replacement The Redundant Intelligence Module is in control On Battery Shutdown or unable to transfer to battery due to overload Load Shutdown from Bypass. Input Frequency Volts outside limits Fault, Internal Temp exceeded system normal limits Input Circuit Breaker Open System level fan failed Bad Battery Module Bad Power Module Intelligence Module is installed and failed Redundant Intelligence Module is installed and failed Redundancy has been lost Redundancy is below alarm threshold Runtime is below alarm threshold Load is above alarm threshold Load is no longer above alarm Threshold Minimum Runtime restored Bypass is not in range (either frequency or voltage) Backfeed contactor stuck in OFF position Backfeed contactor stuck in ON position UPS in Bypass due to Internal Fault UPS in Bypass due to overload System in Forced Bypass Fault, Bypass Relay Malfunction High DC Warning 05/2009 edition ch. 6 – spec6 – p. 6 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy 43. High DC Shutdown 44. Low Battery Shutdown 45. Low Battery Warning F. Controls: The following controls or programming functions shall be accomplished by use of the display unit. Pushbutton membrane switches shall facilitate these operations. 1. 2. 3. 4. 5. 6. 7. 8. G. Silence audible Alarm Display or set the date and time Enable or disable the automatic restart feature Transfer critical load to and from static bypass Test battery condition on demand Set intervals for automatic battery tests Adjust set points for different alarms Program the parameters for remote shutdown. Potential Free (Dry) Contacts 1. The following potential free contacts shall be available on an optional relay interface board: a. Normal Operation b. Battery Operation c. Bypass Operation d. Common Fault e. Low Battery f. UPS Off H. Communication Interface Board: A communication interface board shall provide the following communication ports which can be used simultaneously: 1. RS232 Serial Port #1 2.8 BATTERY A. The UPS battery shall be of modular construction made up of user replaceable, hot swappable, fused, battery modules. Each battery module shall be monitored for voltage and temperature for use by the UPS battery diagnostic, and temperature compensated charger circuitry. B. The battery jars housed within each removable battery module shall be of the Valve Regulated Lead Acid (VRLA) type. C. The UPS shall incorporate a battery management system to continuously monitor the health of each removable battery module. This system shall notify the user in the event that a failed or weak battery module is found. APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 7 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy PART 3 - ACCESSORIES 3.1 BATTERY DISCONNECT BREAKER A. Each UPS system shall have a 320A 500VDC rated, thermal magnetic trip molded case circuit breaker. Each circuit breaker shall be equipped shunt trip mechanisms and 1A/1B auxiliary contacts. The circuit breakers are to be located within the UPS enclosure or as part of a line-up-andmatch type battery cabinet. 3.2 MAINTENANCE BYPASS A. A maintenance bypass shall provide power to the critical load bus from the bypass source, during times where maintenance or service of the UPS is required. A 315A GL fuse must be in front of the Mains input and if dual mains a 250 A gL fuse on the bypass input must be installed. 3.3 SOFTWARE AND CONNECTIVITY A. Network Adaptor: The Ethernet Web/SNMP Adaptor shall allow one or more network management systems (NMS) to monitor and manage the UPS in TCP/IP network environments. The management information base (MIB) shall be provided in DOS and UNIX "tar" formats. B. Unattended Shutdown 1. The UPS, in conjunction with the network adaptor, shall be capable of gracefully shutting down one or more operating systems. 2. The UPS shall also be capable of using an RS232 port to communicate by means of serial communications to gracefully shut down one or more operating systems during an on battery situation. 3.4 REMOTE UPS MONITORING A. The following three methods of remote UPS monitoring shall be available: 1. Web Monitoring: Remote monitoring shall be available via a web browser such as Internet Explorer. 2. RS232 Monitoring: Remote UPS monitoring shall be possible via either RS232 closure signals from the UPS. or contact 3. Simple Network Management Protocol (SNMP): Remote UPS Monitoring shall be possible through a standard MIB II compliant platform. 3.5 SOFTWARE COMPATIBILITY A: The UPS manufacturer shall have available software to support graceful shutdown and remote monitoring for the following systems: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. APC by Schneider Electric Microsoft Windows 95/98/XP Microsoft Windows NT 4.0 SP6/2000 OS/2 Netware 3.2 – 5.1 MAC OS 9.04, 9.22, 10 Digital Unix/True 64 SGI 6.0-6.5 SCO UNIX SVR4 2.3, 2.41 SCO Unix Ware 7.0 - 7.11 SUN Solaris 2.6-2.8 SUN OS 4.13, 4.14 IBM AIX 4.3x-4.33g, 5.1 HP-UX 9.x-11.i 05/2009 edition ch. 6 – spec6 – p. 8 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy Part 4 - EXECUTION 4.1 FACTORY ASSISTED START-UP If a factory assisted UPS start-up is requested, factory trained service personnel shall following inspections, test procedures, and on-site training: A. Visual Inspection: 1. 2. 3. 4. 5. B. perform the Inspect equipment for signs of damage. Verify installation per manufacturer s instructions. Inspect cabinets for foreign objects. Inspect Battery Units. Inspect Power Modules. Mechanical Inspection: 1. Check all UPS and external maintenance bypass internal control wiring connections. 2. Check all UPS and external maintenance bypass internal power wiring connections. 3. Check all UPS and external maintenance bypass terminal screws, nuts, and/or spade lugs for tightness. C. Electrical Inspection: 1. 2. 3. 4. 5. 6. D. Site Testing: 1. 2. 3. 4. 5. 6. 7. 8. 9. E. Verify correct input and bypass voltage. Verify correct phase rotation of all mains connections. Verify correct UPS control wiring and terminations Verify voltage of all battery modules. Verify neutral and ground conductors are properly landed. Inspect external maintenance bypass switch for proper terminations and phasing. Ensure proper system start-up. Verify proper firmware control functions. Verify proper firmware bypass operation. Verify proper maintenance bypass switch operation. Verify system set points. Verify proper inverter operation and regulation circuits. Simulate utility power failure. Verify proper charger operation. Document, sign, and date all test results. On-Site Operational Training: During the factory assisted start-up, operational training for site personnel shall include key pad operation, LED indicators, start-up and shutdown procedures, maintenance bypass and AC disconnect operation, and alarm information. 4.2 MANUFACTURER FIELD SERVICE 4.3 A. Worldwide service: The UPS manufacturer shall have a worldwide service organization Available, consisting of factory trained field service personnel to perform start-up, preventative maintenance, and service of the UPS system and power equipment. The service organization shall offer 24 hours a day, 7 days a week, 365 days a year service support. B. Replacement parts: Parts shall be available through the worldwide service organization 24 hours a day, 7 days a week, 365 days a year. The worldwide service organization shall be capable of shipping parts within 4 working hours or on the next available flight, so that the parts may be delivered to the customer site within 24 hours. MAINTENANCE CONTRACTS APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 9 Specification guide no. 6 Modular UPS system, three-phase, 16 to 48/160 kW* * maximum power rating without redundancy A complete offering of preventative and full service maintenance contracts for the UPS system and the battery system shall be available. All contract work shall be performed by factory trained service personnel. 4.4 TRAINING UPS service training workshop: A UPS service training workshop shall be available from the UPS manufacturer. The service training workshop shall include a combination of lecture and practical instruction with hands-on laboratory sessions. The service training workshop shall include instruction about safety procedures, UPS operational theory, sub-assembly identification and operation, system controls and adjustment, preventative maintenance, and troubleshooting. APC by Schneider Electric 05/2009 edition ch. 6 – spec6 – p. 10 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy PART 1 - GENERAL 1.1 SUMMARY A. This specification describes the operation and functionality of a continuous duty, three-phase, solid-state, on-line double conversion static Uninterruptible Power System (UPS) hereafter referred to as the UPS. The UPS shall utilize a rack-mounted N+1 redundant, scalable array architecture. The system power train shall be comprised of 25kVA/25kW power modules and be capable of being configured for N+X redundant operation at the rated system load. In systems operating at a load where the system is N+1 or greater, the UPS shall facilitate the replacement of power modules while the system remains in normal operation, without the requirement to transfer to bypass (hot swappable). B. Each 25kVA/25kW power module contains a fully rated, power factor corrected input rectifier / boost converter hereafter referred to as the PFC input stage, a fully rated output inverter, and battery charging circuit. The system shall also be comprised of a hot swappable continuous duty bypass static switch module, redundant control modules, redundant logic power supplies, and touch screen user interface/display. Hot swappable / user replaceable battery modules shall be available as an option. All of the above system components are housed in a standard 600mm (W) x 1070mm(D) x 2000mm(H) equipment rack. C. In addition, this specification describes the performance, functionality, and design of the UPS Maintenance Bypass Cabinet with output distribution, hereafter referred to as the MBwD and the Battery System. D. The UPS and associated equipment shall operate in conjunction with a primary power supply and an output distribution system to provide quality uninterrupted power for mission critical, electronic equipment load. E. D. All programming and miscellaneous components for a fully operational system as described in this specification shall be available as part of the UPS. 1.2 STANDARDS A. Safety: 1. IEC 60950-1 / EN 60950-1 Information technology equipment - Safety - Part: General requirements 2. IEC 62040-1/ EN 62040-1 Uninterruptible power systems (UPS) - General and safety requirements for UPS. 3. IEC 62040-3 / EN 1000-3 Uninterruptible power systems (UPS) - Method of specifying the test and performance requirements. 4. IEC 60439 Low-voltage switchgear and controlgear assemblies. 5. LV directive: 2006/95/EC B. Harmonics: 1. IEC 61000-2-2 / EN 61000-2-2 Compatibility levels for low-frequency conducted disturbances and signalling in public low-voltage power supply systems. 2. IEC 61000-3-2 / EN 61000-3-2 Limits for harmonic current emissions (equipment input current ≤ 16 A/ph). 3. IEC 61000-3-4 / EN 61000-3-4 Limits for harmonic current emissions (equipment input current > 16 A/ph). 4. IEC 61000-3-5 / EN 61000-3-5 Limitation of voltage fluctuations and flicker. 5. EN 50160 Voltage characteristics of public networks. 6. IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 1 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy C. EMC: 1. EN 50091-2 UPS - EMC. 2. IEC 62040-2/ EN 62040-2 Uninterruptible power systems (UPS) - Electromagnetic compatibility (EMC) requirements. 3. EMC Directive 2004/108/EC For equipment liable to cause or be affected by electromagnetic disturbances. D. Quality: 1. Design , production and servicing in compliance with standard ISO 9001 - quality organisation. E. Ecological environment: 1. Manufacturing in compliance with standard ISO 14001. F. Acoustic noise 1. ISO 3746 Sound power levels. 2. ISO 7779 / EN 27779 Measurement of airborne noise emitted by computer and business equipment. 1.3 MODES OF OPERATION A. Normal: The PFC Input stage and output inverter shall operate in an on-line manner to continuously regulate power to the critical load. The input and output converters shall be capable of full battery recharge while simultaneously providing regulated power to the load for all line and load conditions within the range of the UPS specifications. B. Battery: Upon failure of the AC input source, the critical load shall continue being supplied by the output inverter, which shall derive its power from the battery system. There shall be no interruption in power to the critical load during both transfers to battery operation and retransfers from battery to normal operation. Upon restoration of utility power to the UPS input, the UPS shall recharge the battery C. Static Bypass: The static bypass shall be used to provide controller transfer of critical load from the inverter output to the bypass source. This transfer, along with its retransfer, shall take place with no power interruption to the critical load. In the event of a UPS output fault or significant output overload emergency, this transfer shall be an automatic function. Manual transfer to Static Bypass (called “Requested bypass”) shall be available in order to facilitate a controlled transfer to Maintenance Bypass. E. Maintenance Bypass: The system can be equipped with an optional integrated, bus connected external make-before-break Maintenance Bypass Cabinet (MBwD) to electrically isolate the UPS during routine maintenance and service of the UPS. The MBwD shall allow for the completely electrical isolation of the UPS. An option for an external make-before-break external maintenance bypass panel shall be available 1.4 SUBMITTALS A. Proposal Submittals: 1. As bid system bill of materials. 2. Product catalog sheets or equipment brochures. 3. Product guide specifications. 4. System single-line operation diagram. 5. Installation information, including weights and dimensions. 6. Information about terminal locations for power and control connections. 7. Drawings for requested optional accessories. B. Delivery Submittals: 1. Installation manual, which includes instructions for storage, handling, examination, preparation, installation, and start-up of UPS. 2. User manual, which includes operating instructions. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 2 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy PART 2 – PRODUCT 2.1 DESIGN REQUIREMENTS A. The UPS shall be sized for _____ kVA and _____ kW load. B. The UPS battery shall be sized for _____kW at a Power Factor of_____ for _____ minutes. 2.2 SYSTEM CHARACTERISTICS A. System Capacity: The system shall be rated for full kW output in the following frame sizes: 1. 250 kVA/kW- Can be configured with up to ten, 25kW power modules for 250 kW or 225 kW N+1 2. 500 kVA/kW - Can be configured with up to twenty, 25 kW modules for 500kW or 475 kW N+1 B. Input: The system input shall be configurable as either single or dual mains derived from a three phase Wye source. Standard cable entry is through the top. Bottom cable entry can also be facilitated. Depending on the specific configuration, the use of the optional Bottom Feed Enclosure may be required. An option shall be available to facilitate the connection of NEMA 2 compression lugs for main input, bypass input, DC input and output cable connections 1. AC Input Nominal Voltage: System voltage shall be selectable at the front panel by service personnel with the following options: 380V , 400V and 415V 2. AC Input Voltage Window: +/-15% for full performance -20% with reduced charge power -50% for reduced load 3. Short Circuit Withstand Rating: 65,000 Symmetrical Amperes 4. Maximum Frequency Range: 40-70Hz Frequency is synchronized to bypass input when available over the standard range of 50 or 60 Hz +/- 3 Hz. Optional frequency tolerance range is configurable from 0.5% to 8% from front panel. 5. Input Power Factor: Greater than 0.995 with load at 100% Greater than 0.99 with loads above 50% Greater than 0.97 with loads above 25% 6. Input current in Normal operation shall be limited to a maximum of 137% of the system capacity 7. Input current Distortion with no additional filters: Less than 5% 8. Soft-Start: Shall be linear from 0-100% input current and shall not exhibit inrush. This shall take place over a user selectable 1-60 second time period with a factory default of 10 seconds. C. UPS Output: 1. AC Input Nominal Voltage: System voltage shall be selectable at the front panel by service personnel with the following options: 380V , 400V and 415V APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 3 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy 2. AC Output Voltage Distortion: Less than. 2% @ 100% Linear Load. Less than 6% for SMPS load as defined by EN50091-3/IEC 62040-3 3. AC Output Voltage Regulation: +/- 1% For 100 % Linear or Nonlinear Load 4. Voltage Transient Response: +/-5% maximum RMS change in a half cycle at load step 0% to 100% or 100% to 0%. 5. Voltage Transient Recovery within <50 milliseconds 6. Output Voltage Harmonic Distortion: a. <2% THD maximum and 1% single harmonic for a 100% linear load 7. Phase Angle Displacement: a. 120 degrees +/-1 degree for balanced load b. 120 degrees +/-1 degrees for 50% imbalanced load c. 120 degrees +/-3 degrees for 100% imbalanced load 8. Overload Rating: a. Normal Operation: 1) 150% for 30 seconds before transfer to Bypass or 2) 125% for 10 minutes before transfer to bypass b. Battery operation 1) 125% for 30 seconds c. Bypass Operation: 1) 125% continuous at 480V 2) 1000% for 100 milliseconds 9. System AC-AC Efficiency: Normal operation > 96% at 40% - 100% load Battery operation > 95% at 40% to 100% load 10. Output Power Factor Rating: 0.5 leading to 0.5 lagging without any derating 2.3 ENVIRONMENTAL A. Storage Ambient Temperature: -15 to 40°C (-30 to 70°C without batteries) B. Storage relative Humidity: 0-95% C. Operating Ambient Temperature: 0°C to 40°C. (25° C is ideal for most battery types). D. Operating Relative Humidity: 0 to 95% Non-condensing E. Altitude: Maximum installation with no derating of the UPS output shall be 3,000 feet (1000m) above sea level. The UPS capacity shall be derated for altitude as follows: 1500 m 95% Load 2000 m91% Load 2500 m 86% Load 3000 m 82% Load F. Audible Noise (as measured three feet from surface) 54 dBA at 100% load 45 dBA at 70% load APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 4 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy 2.4 PFC INPUT STAGE A. The PFC Input stage converters of the system are housed within the removable power modules, and shall constantly control the power imported from the mains input of the system, to provide the necessary UPS power for precise regulation of the DC bus voltage, battery charging, and Main Inverter regulated output power. These power modules are connected in parallel within the UPS frame. B. Input Current Total Harmonic Distortion: The input current THDI shall be held to less than 5% at system load greater than 50% while providing conditioned power to the critical load bus, and charging the batteries under steady-state operating conditions. This shall be true while supporting both a linear or non-linear loads. This shall be accomplished without the requirement for additional or optional filters, magnetic devices, or other components. C. Soft-Start Operation: As a standard feature, the UPS shall contain soft-start functionality, capable of limiting the input current from 0-100% of the nominal input over a default 10 second period, when returning to the AC utility source from battery operation. The change in current over the change in time shall take place in a linear manner throughout the entire operation. D. Magnetization Inrush Current: The UPS shall exhibit zero (0) inrush current. E. Input Current Limit: 1. The PFC Input stage shall control and limit the input current draw from utility to 137% of the UPS output. During conditions where input current limit is active, the UPS shall be able to support 100% load, charge batteries at 10% of the UPS output rating, and provide voltage regulation with mains deviation -15% 2. In cases where the source voltage to the UPS is nominal and the applied UPS load is equal to or less than 100% of UPS capacity, input current shall not exceed 116% of UPS output current, while providing full battery recharge power and importing necessary power to account for system losses. F. Redundancy: The UPS shall be capable of being configured with redundant PFC Input stages, each with semiconductor fusing, and logic controlled contactors to isolate a failed module from the input bus. G. Charging: 1. The battery charging shall keep the DC bus float voltage of +/- 327v, +/-1% 2. The battery charging circuit shall contain a temperature compensation circuit, which will regulate the battery charging to optimize battery life. 3. The battery charging circuit shall remain active when in Static Bypass and in Normal Operation. 4. The UPS shall be capable of reducing the battery charging current under low input voltage conditions 5. Battery charge shall be limited to 10% of the system capacity by default. The UPS shall be capable of recharging the battery at a capacity up to 20% of the system power capacity at reduced loads 6. The UPS shall be capable being programmed to reduce battery charging current in normal operation by 10% or 20% by service personnel H. Back-feed Protection: The above-mentioned logic controlled contactor also provides back-feed protection. 2.5 OUTPUT INVERTER A. The UPS output inverter shall constantly develop the UPS output voltage waveform by converting the DC bus voltage to AC voltage through a set of IGBT driven bi-directional power converters. In both normal operation and battery operation, the output inverters shall create an output voltage independent of the mains input voltage. Input voltage anomalies such as brown-outs, spikes, surges, sags, and outages shall not affect the amplitude or sinusoidal nature of the output voltage sine wave of the inverters. B. Overload Capability: The output power converters shall be capable of 230% for short circuit clearing. Steady-state overload conditions, of up to 150% of system capacity shall be sustained by the inverter for 30 seconds in normal operation. Overloads persisting past the outlined time limitation the critical load will be switched to the automatic static bypass output of the UPS. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 5 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy C. Output Contactor: The output inverter shall be provided with an output mechanical contactor to provide physical isolation of the inverter from the critical bus. With this feature a failed inverter shall be isolated from the critical bus. D. Battery Protection: The inverter shall be provided with monitoring and control circuits to limit the level of discharge on the battery system. E. Redundancy: The UPS shall be capable of being configured with redundant output inverters, each with semiconductor fusing, and logic controlled contactors to remove a failed component from the input, DC and output critical bus. 2.6 STATIC BYPASS A. As part of the UPS, a system static bypass switch shall be provided. The system static bypass shall provide no break transfer of the critical load from the Inverter output to the static bypass input source during times where maintenance is required, or the inverter can not support the critical bus. Such times may be due to prolonged or severe overloads, or UPS failure. The UPS and static bypass switch shall constantly monitor the auxiliary contacts of their respective circuit breakers, as well as the bypass source voltage, and inhibit potentially unsuccessful transfers to static bypass from taking place. B. The design of the static switch power path shall consist of Silicon Controlled Rectifiers (SCR) with a continuous duty rating of 125% at 480V of the UPS output rating. C. Automatic Transfers: An automatic transfer of load to static bypass shall take place whenever the load on the critical bus exceeds the overload rating of the UPS. Automatic transfers of the critical load from static bypass back to normal operation shall take place when the overload condition is removed from the critical bus output of the system. Automatic transfers of load to static bypass shall also take place if for any reason the UPS cannot support the critical bus. D. Manual Transfers: Manually initiated transfers to and from static bypass shall be initiated through the UPS graphical user interface. E. Overloads: The static bypass shall be rated and capable of handling overloads equal to or less than 125% at 480V of the rated system output continuously. For instantaneous overloads caused by inrush current from magnetic devices, or short circuit conditions, the static bypass shall be capable of sustaining overloads of 1000% of system capacity for periods of up to 100 milliseconds. F. Modular: The static bypass switch shall be of a modular design. G. System Protection: Back-feed protection in the static bypass circuit shall also be incorporated in the system design. To achieve back-feed protection, a mechanical contactor in series with the bypass SCR(s) shall be controlled by the UPS/static switch, to open immediately upon sensing a condition where back-feeding of the static switch by any source connected to the critical output bus of the system is occurring. One such condition could be a result of a shorted SCR. 2.7 DISPLAY AND CONTROLS A. Control Logic: The UPS shall be controlled by two fully redundant, user-replaceable / hot-swappable Intelligence modules (IM). These modules shall have separate, optically isolated, communication paths to the power and static switch modules. Logic power for the control modules shall be derived from redundant power supplies, each having a separate AC and DC input and output. The communication of the control modules shall be of Controller Area Network (CAN Bus) and EIA485. B. Graphical User Interface: A microprocessor controlled user interface/display unit shall be located on the front of the system. The display shall consist of a 10.4 inch multicolor graphical display with 800x600 resolution. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 6 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy C. Metered Data: the following data shall be available on the Graphical User Interface/display: Input\Output Voltages, Currents, Frequencies Breaker & Switch Status Battery Status Event Log D. Event log: The display unit shall allow the user to display a time and date stamped log. E. Alarms: The display unit shall allow the user to display a log of all active alarms. The following minimum set of alarm conditions shall be available: 1. Input Frequency outside configured range 2. AC adequate for UPS but not for Bypass 3. Low/No AC input, startup on battery 4. Intelligence Module inserted 5. Intelligence Module removed 6. Redundant Intelligence Module inserted 7. Redundant Intelligence Module removed 8. Number of Batteries changed since last ON 9. Number of Power Modules changed since last ON 10. Number of Batteries increased 11. Number of Batteries decreased 12. Number of Power Modules increased 13. Number of Power Modules decreased 14. Number of External Battery Cabinets increased 15. Number of External Battery Cabinets decreased 16. Redundancy Restored 17. Need Battery Replacement 18. The Redundant Intelligence Module is in control 19. UPS Fault 20. On Battery 21. Shutdown or unable to transfer to battery due to overload 22. Load Shutdown from Bypass. Input Frequency Volts outside limits 23. Fault, Internal Temp exceeded system normal limits 24. Input Circuit Breaker Open 25. System level fan failed 26. Bad Battery Module 27. Bad Power Module 28. Intelligence Module is installed and failed 29. Redundant Intelligence Module is installed and failed 30. Redundancy has been lost 31. Redundancy is below alarm threshold 32. Runtime is below alarm threshold 33. Load is above alarm threshold 34. Load is no longer above alarm Threshold 35. Minimum Runtime restored 36. Bypass is not in range (either frequency or voltage) 37. Backfeed contactor stuck in OFF position 38. Backfeed contactor stuck in ON position 39. UPS in Bypass due to Internal Fault 40. UPS in Bypass due to overload 41. System in Forced Bypass 42. Fault, Bypass Relay Malfunction 43. Q001 open/closed 44. Q002 open/closed 45. Q003 open/closed 46 Q005 open/closed 47. High DC Warning 48. High DC Shutdown 49. Low Battery Shutdown 50. Low Battery Warning 51. MBwD door open APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 7 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy F. Controls: The following controls or programming functions shall be accomplished by the use of the user interface/display unit. The touch screen display shall facilitate these operations: 1. 2. 3. 4. 5. 6. 7. 8. G. Silence audible Alarm Display or set the date and time Enable or disable the automatic restart feature Transfer critical load to and from static bypass Test battery condition on demand Set intervals for automatic battery tests Adjust set points for different alarms Potential Free (Dry) Contacts The following potential free contacts shall be available on an optional relay interface board: 1. 2. 3. 4. 5. 6. Normal Operation Battery Operation Bypass Operation Common Fault Low Battery UPS Off H. Communication Interface Board: A communication interface board shall provide the following communication ports which can be used simultaneously: 1. Ethernet 2. Ethernet Interface port for a Remote Display 3. MODBUS 2.8 BATTERY A. The UPS battery shall support an optional battery plant of modular construction made up of user replaceable, hot swappable, fused, battery modules. Each battery module shall be monitored for voltage and temperature for use by the UPS battery diagnostic. Battery charging current shall be temperature compensated. B. The battery jars housed within each removable battery module shall be of the Valve Regulated Lead Acid (VRLA) type. C. The UPS shall incorporate a battery management system to continuously monitor the status of each removable battery module. This system shall notify the user in the event a failed or weak battery module is found. D. The Batteries shall be long life batteries (5-8 year) and the battery casing shall be flame retardant type. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 8 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy PART 3 – ACCESSORIES 3.1 BATTERY BREAKER CABINET A. To facilitate third party battery configuration, a battery breaker cabinet in a line up netshelter enclosure shall be available. Each cabinet will monitor breaker status and battery temperature. Each circuit breaker shall be equipped shunt trip mechanisms and 1A/1B auxiliary contacts. The Battery Breaker Cabinet shall accommodate top or bottom entry for cables. 3.2 MAINTENANCE BYPASS CABINET (MBwD) A. The maintenance bypass cabinet shall provide power to the critical load bus from the bypass source, during times where maintenance or service of the UPS is required. The MBwD shall provide a mechanical means of complete isolation of the UPS from the electrical wiring of the installation and will be mounted to the systems I/O frame. B. As a minimum, the MBwD shall contain the following features and accessories: 1. Circuit breakers of the appropriate size, withstand rating (50kAIC rating), and trip rating for the system. 2. Minimum 1A/1B auxiliary contacts for the purpose of relaying status information of each circuit breaker / switch actuator to the UPS and static bypass. 3. Plated copper bus bar (where applicable), braced for the appropriate withstand rating (50 kAIC rating) of the system. C. The following minimum options shall also be available for the MBC: 1. Mimic label with light indications for power flow. 3.3 REMOTE BATTERIES The modular batteries shall have the capability to be located remote to the UPS. In such installations, an optional side car shall be used to connect the batteries by cables to the UPS. The battery side car shall accommodate top or bottom cable entry. The side car will have over current fuses to protect the cables. The fuse status shall be monitored by the UPS. 3.4 BOTTOM FEED ENCLOSURE For installations greater than 250kW, a bottom feed enclosure shall provide the mechanical means necessary to support bottom feeds for specific system configurations. 3.5 RELAY BOARD A relay boards shall be provided for customer connections to external alarms or to activate external customer circuits. 3.6 SOFTWARE AND CONNECTIVITY A. Network Adaptor: The Ethernet Web/SNMP Adaptor shall allow one or more network management systems (NMS) to monitor and manage the UPS in TCP/IP network environments. The management information base (MIB) shall be provided in DOS and UNIX "tar" formats. The SNMP interface adaptor shall be connected to the UPS via the RS232 serial port on the standard communication interface board. B. Unattended Shutdown 1. The UPS, in conjunction with a network interface card, shall be capable of gracefully shutting down one or more operating systems during when the UPS is operation from the battery. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 9 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy 3.7 REMOTE UPS MONITORING A. The following three methods of remote UPS monitoring shall be available: 1. Web Monitoring: Remote monitoring shall be available via a web browser such as Internet Explorer. 2. Remote UPS monitoring shall be possible via MODBUS 3. Simple Network Management Protocol (SNMP): Remote UPS Monitoring shall be possible through a standard MIB II compliant platform . 3.8 SOFTWARE COMPATIBILITY A. The UPS manufacturer shall have available software to support remote monitoring and initiate the graceful shutdown for the following systems: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. APC by Schneider Electric Microsoft Windows 95/98/XP Microsoft Windows NT 4.0 SP6/2000 OS/2 Netware 3.2 – 5.1 MAC OS 9.04, 9.22, 10 Digital Unix/True 64 SGI 6.0-6.5 SCO UNIX SVR4 2.3, 2.41 SCO Unix Ware 7.0 - 7.11 SUN Solaris 2.6-2.8 SUN OS 4.13, 4.14 IBM AIX 4.3x-4.33g, 5.1 HP-UX 9.x-11.i 05/2009 edition ch. 6 – spec. 7 – p. 10 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy Part 4 - EXECUTION 4.1 FACTORY ASSISTED START-UP Factory startup shall be included, factory trained service personnel shall perform the following inspections, test procedures, and on-site training: A. Visual Inspection: 1. Inspect equipment for signs of damage. 2. Verify installation per manufacturer s instructions. 3. Inspect cabinets for foreign objects. 4. Inspect Battery Units. 5. Inspect Power Modules. B. Mechanical Inspection: 1. Check all UPS and external maintenance bypass cabinet internal control wiring connections. 2. Check all UPS and external maintenance bypass cabinet internal power wiring connections. 3. Check all UPS and external maintenance bypass cabinet terminal screws, nuts, and/or spade lugs for tightness. C. Electrical Inspection: 1. Verify correct input and bypass voltage. 2. Verify correct phase rotation of all mains connections. 3. Verify correct UPS control wiring and terminations. 4. Verify voltage of all battery modules. 5. Verify neutral and ground conductors are properly landed. 6. Inspect external maintenance bypass switch for proper terminations and phasing. D. Site Testing: 1. Ensure proper system start-up. 2. Verify proper firmware control functions. 3. Verify proper firmware bypass operation. 4. Verify proper maintenance bypass switch operation. 5. Verify system set points. 6. Verify proper inverter operation and regulation circuits. 7. Simulate utility power failure. 8. Verify proper charger operation. 9. Document, sign, and date all test results. E. On-Site Operational Training: During the factory assisted start-up, operational training for site personnel shall include touch screen operation, LED indicators, start-up and shutdown procedures, maintenance bypass and AC disconnect operation, and alarm information. 4.2 MANUFACTURER’S FIELD SERVICE A. Worldwide service: The UPS manufacturer shall have a worldwide service organization Available, consisting of factory trained field service personnel to perform start-up, preventive maintenance, and service of the UPS system and power equipment. The service organization shall offer 24 hours a day, 7 days a week, 365 days a year service support. B. Replacement parts: Parts shall be available through the worldwide service organization 24 hours a day, 7 days a week, 365 days a year. The worldwide service organization shall be capable of shipping parts within 4 working hours or on the next available flight, so that the parts may be delivered to the customer site within 24 hours. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 11 Specification guide no. 7 Modular UPS system, three-phase, 25 to 500 kW* * maximum power rating without redundancy 4.3 MAINTENANCE CONTRACTS A complete offering of preventative and full service maintenance contracts for the UPS system and the battery system shall be available. All contract work shall be performed by factory trained service personnel. 4.4 TRAINING UPS service training workshop: A UPS service training workshop shall be available from the UPS manufacturer. The service training workshop shall include a combination of lecture and practical instruction with hands-on laboratory sessions. The service training workshop shall include instruction about safety procedures, UPS operational theory, sub-assembly identification and operation, system controls and adjustment, preventive maintenance, and troubleshooting and trainer user level repair. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 7 – p. 12 Specification guide no. 8 Scalable UPS system, three-phase, 400 to 1600/4000 kW* * maximum power rating without redundancy PART 1 - GENERAL 1.1 SUMMARY A. This specification describes the operation and functionality of a continuous duty, three-phase, solidstate, static Uninterruptible Power Supply (UPS) hereafter referred to as the UPS. The UPS control logic shall incorporate state of the art Digital Signal Processing. The Inverters shall utilize high speed pulse-width-modulation and be constructed of IGBT’s. The UPS shall be part of a multi-module system, and function as described in this specification. B. In addition, this specification describes the performance, functionality, and design of the UPS Maintenance Bypass Cabinet, hereafter referred to as the MBC, the Battery System, UPS paralleling gear, External Bypass Static Switch (EBS), and other such electrical distribution as described in this specification. C. The UPS and associated equipment shall operate in conjunction with a primary power supply (utility and/or on-site generation) and an output distribution system to provide quality uninterrupted power for mission critical, electronic equipment load. D. All owner/engineer selected accessories programming and miscellaneous components for a fully operational system as described in this specification shall be supplied as part of the UPS at no additional cost. 1.2 STANDARDS A. Safety: 1. IEC 60950-1 / EN 60950-1 Information technology equipment - Safety - Part: General requirements 2. IEC 62040-1/ EN 62040-1 Uninterruptible power systems (UPS) - General and safety requirements for UPS. 3. IEC 62040-3 / EN 1000-3 Uninterruptible power systems (UPS) - Method of specifying the test and performance requirements. 4. IEC 60439 Low-voltage switchgear and controlgear assemblies. 5. LV directive: 2006/95/EC B. Harmonics: 1. IEC 61000-2-2 / EN 61000-2-2 Compatibility levels for low-frequency conducted disturbances and signalling in public lowvoltage power supply systems. 2. IEC 61000-3-2 / EN 61000-3-2 Limits for harmonic current emissions (equipment input current ≤ 16 A/ph). 3. IEC 61000-3-4 / EN 61000-3-4 Limits for harmonic current emissions (equipment input current > 16 A/ph). 4. IEC 61000-3-5 / EN 61000-3-5 Limitation of voltage fluctuations and flicker. 5. EN 50160 Voltage characteristics of public networks. 6. IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 8 – p. 1 Specification guide no. 8 Scalable UPS system, three-phase, 400 to 1600/4000 kW* * maximum power rating without redundancy C. EMC: 1. EN 50091-2 UPS - EMC. 2. IEC 62040-2/ EN 62040-2 Uninterruptible power systems (UPS) - Electromagnetic compatibility (EMC) requirements. 3. EMC Directive 2004/108/EC For equipment liable to cause or be affected by electromagnetic disturbances. D. Quality: 1. Design , production and servicing in compliance with standard ISO 9001 - quality organisation. E. Ecological environment: 1. Manufacturing in compliance with standard ISO 14001. F. Acoustic noise 1. ISO 3746 Sound power levels. 2. ISO 7779 / EN 27779 Measurement of airborne noise emitted by computer and business equipment. 1.3 MODES OF OPERATION A. Normal: 1. The Main Inverter and Delta Inverter shall operate in an on-line manner to continuously regulate and supply power to the critical load. The input power converter and output inverter shall be capable of full battery recharge while simultaneously providing 100% regulated power to the load bus for all line and load conditions within the range of the UPS specifications. 2. Recharge: Upon restoration of the Utility or on-site electrical generation AC input source, the input power converter and output inverter shall simultaneously recharge the battery and continue to provide 100% regulated power to the critical load bus. 3. Auto Restart: The UPS shall have an Auto Restart function which, when enabled, will allow the UPS to be automatically restarted and placed on-line upon the restoration of input power. Should the input power fail to return within four hours, the UPS shall automatically open the battery disconnects to prevent excessive battery discharge. B. Battery: Upon utility or on site electrical generation input failure or any out of tolerance condition as defined by this specification of the electrical AC input source, the critical load bus shall continue being supplied by the main inverter, which shall derive its power from the battery system. There shall be no interruption of power to the critical load bus during both transitions to battery operation and from battery to normal operation. C. Static Bypass: The static bypass shall be used to provide a seamless transfer of the critical load bus from the Inverter output to the bypass source. This transfer, along with its retransfer, shall take place with no power interruption to the critical load bus. In the event of an extreme overload condition, inverter output voltage out of tolerance condition or if commanded by the operator. This transfer shall be an automatic function with the exception of an operator initiated transfer. The UPS shall automatically return to normal operation when the overload or out of tolerance condition is cleared D. Maintenance Bypass: The UPS system shall be equipped with an external Maintenance Bypass Cabinet (MBC) to electrically isolate the UPS during routine maintenance and service of the UPS. The MBC shall completely isolate both the UPS(s) input and output connections. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 8 – p. 2 Specification guide no. 8 Scalable UPS system, three-phase, 400 to 1600/4000 kW* * maximum power rating without redundancy 1.4 SUBMITTALS A. Proposal Submittals: 1. 2. 3. 4. 5. 6. 7. B. As bid system bill of materials. Product catalog sheets or equipment brochures. Product guide specifications. System single-line operation diagram. Installation information, including weights and dimensions. Information about terminal locations for power and control connections. Drawings for requested optional accessories. Delivery Submittals: 1. Installation manual, which includes instructions for storage, handling, examination, preparation and installation of UPS. 2. User manual, which includes operating instructions. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 8 – p. 3 Specification guide no. 8 Scalable UPS system, three-phase, 400 to 1600/4000 kW* * maximum power rating without redundancy PART 2 – PRODUCT 2.1 DESIGN REQUIREMENTS A. The UPS system shall be sized for a total load capacity of ________ kW. Each frame shall be rated for __________ kW with ________ redundant UPS modules B. Each UPS module shall be sized for a load capacity of _______ kW load and quantity of ______ 200 kW redundant UPS section(s). C. The UPS battery shall be sized for an output of _____ kW ____ at a Power Factor of ________ for ________ minutes. 2.2 SYSTEM CHARACTERISTICS A. Multi-Module UPS Capacity: The system shall be rated for full kW output in the 1. 2. 3. 4. 5. 6. 7. following sizes: 400kVA/400kW 600kVA/600kW 800kVA/800kW 1000kVA/1000 kW 1200kVA/1200 kW 1400kVA/1400kW 1600kVA/1600kW It shall be possible to connect multiple units in parallel to provide an output of 4000 kW. B. Electrical Input: 1. AC Input Nominal Voltage: 380 / 400 / 415 V, 3 Phase, 3 wire, 50 or 60 Hz. + 2. AC Input Voltage Window: /- 15% of nominal (while providing nominal charging to the battery system). 3. Short Circuit Withstand Rating: 200,000 Symmetrical Amperes (200 kA) + 4. Maximum Frequency Range: /- .5%- 8% of nominal 5. Input Power Factor: Approximately ~1at 100% load and shall not be less than 0.99 at loads greater than 25% of system rating with no additional filters. 6. Input Current Distortion: Maximum 5% with no requirement for optional additional filters 7. Soft-Start: Input current shall be linear from 0-100% input. This shall take place over a 10 second default time and values from 1-40 seconds shall be programmable. The UPS shall exhibit no magnetizing inrush current. C. UPS Electrical Output: 1. AC Output Nominal Output: 380 / 400 / 415 V, 3 Phase, 3 wire, 50 or 60 Hz. 2. AC Output Voltage Distortion: Max. 3% @ 100% Linear Load. 3. AC Output Voltage Regulation: a. b. + + /- 1% For 100 % Balanced Linear Load /- 3% For 100% Unbalanced Linear Load 4. Voltage Transient Response: a. b. + + /- 3% maximum for 50% load step /- 5% maximum for 100% load step 5. Voltage Transient Recovery within 50 milliseconds APC by Schneider Electric 05/2009 edition ch. 6 – spec. 8 – p. 4 Specification guide no. 8 Scalable UPS system, three-phase, 400 to 1600/4000 kW* * maximum power rating without redundancy 6. Output Voltage Harmonic Distortion: a. 3% THD maximum and 1% single harmonic for a 100% linear load b. 5% THD maximum for a 100% non-linear load c. UPS shall be able to support Unlimited Crest Factor 7. Phase Angle Displacement: a. 120 degrees +/- 1 degree for balanced load + b. 120 degrees /- 1 degrees for 50% imbalanced load + c. 120 degrees /- 3 degrees for 100% imbalanced load 8. Overload Rating: a. Normal Operation: 1) 200% for 60 seconds 2) 125% for 10 minutes b. Battery Operation: 150% for 30 seconds c. Bypass Operation: 1) 125% continuous 2) 1000% for 100 milliseconds 9. UPS Efficiency: With nominal voltage and resistive load. The UPS AC-AC efficiency shall be as follows: At 100% load At 75% Load At 50% Load At 25% Load 97% 97% 96% 94% The UPS DC-AC efficiency shall be as follows: At 100% load At 75% Load At 50% Load At 25% Load 96% 97% 97% 96% 10. Output Power Factor Rating: The UPS output shall not require derating for purely resistive loads (PF of 1). The kW and kVA ratings of the UPS output shall be equal. For loads exhibiting a power factor of .9 leading to .8 lagging no derating of the UPS shall be required. For loads exhibiting power factors outside this range, the following derating shall apply: a. b. c. d. D. 5% derating of the UPS shall apply for 0.7 PF lagging 10% derating of the UPS shall apply for 0.6 PF lagging 15% derating of the UPS shall apply for 0.5 PF lagging 20% derating of the UPS shall apply for a range of 0.4 - 0.1 PF lagging. Design and Construction 1. Printed Circuit Boards: All card edge connected printed circuit boards shall have mechanical interlocks to prohibit a board from being plugged into the wrong place. 2. Electromagnetic Interference: Radiated and conducted EMI generated within the system shall be suppressed to prevent excessive interference with associated nearby electronic equipment. Radio frequency generating equipment external to the system, such as hand held portable radios and other electronic devices, shall not cause a malfunction of the system components when all enclosures are shut. Compliance shall conform to FCC47 part 15 subpart A. 10-1-98 APC by Schneider Electric 05/2009 edition ch. 6 – spec. 8 – p. 5 Specification guide no. 8 Scalable UPS system, three-phase, 400 to 1600/4000 kW* * maximum power rating without redundancy 3. Finish and Painting: a. All external welds shall be ground smooth and all sharp corners eliminated. b. All surfaces shall be clean and smooth and cleared of all blemishes before application of the finish. c. Steel enclosures shall have a finish coat of durable baked enamel. The equipment shall be painted in accordance with Manufacturer's standard procedure. d. Primers for steel surfaces shall be suitable for the service and operating temperatures to be encountered during the life of the equipment. e. Upon Request a can of touch-up paint in each color shall be provided. 4. The UPS assemblies shall be constructed in NEMA Type-1 metal enclosures. Enclosures shall have provisions for forklift handling. The individual enclosures shall be free standing, capable of side-by-side or back-to-back installation with front access requirements only. 2.3 ENVIRONMENTAL A. Storage Ambient Temperature: -50°C to 55°C. B. Operating Ambient Temperature: 0°C to 40°C. (25°C is ideal for most battery types). C. Relative Humidity: 0 to 95% Non-condensing D. Altitude: Maximum installation altitude with no derating of the UPS output shall be 1000m above sea level. At higher altitudes the following derating shall apply: 1. 1500 m derating factor of 0.95 2. 2000 m derating factor of 0.91 3. 2500 m derating factor of 0.86 E. Access Requirements: 1. The UPS shall require front access only for installation and field assembly. Servicing of the UPS shall only require front access for all commonly serviced components, such as fuses, power modules, control circuits, contactors, and all active components. No top, side, or back access is required for servicing said components of the UPS. 2. At user discretion, for UPS’s 1,000 kW and below, power cabling for both the UPS AC and DC shall be top or bottom entry as standard product and shall be terminated in a designated input/output section of the UPS. 3. Replacement of air filters shall not require the system to be placed into maintenance bypass, nor shall it require personnel to be subjected to live voltage potential. 2.4 MODULARITY OF DESIGN A. The UPS shall be of modular design and construction consisting of independent 200kW power converter sections configured from 400 to 1600 kW. Each power section shall consist of three 67kW independent modules. Each power module shall allow easy frontal draw-out accessibility for maintenance or system growth. Each module shall exhibit independent fault tolerance to other modules and shall allow for continuous system operation. B. Redundant Configuration: The UPS internal design shall allow for the selection of one to seven redundant 200kW power module sections for owner selected redundancy level. C. The UPS mechanical and electrical design shall combine to form a fault protection design base. In the unlikely event of an inverter module fault, each module shall be electrically and mechanically protected from the faulted unit and that the faulted unit shall not influence other modules or system operations. Each 200 kW power converter section shall incorporate independent time coordinated fusing with mechanical contactors to facilitate the rapid isolation of a failed section from the input, output, and DC buses, without sacrificing the critical load output bus. APC by Schneider Electric 05/2009 edition ch. 6 – spec. 8 – p. 6 Specification guide no. 8 Scalable UPS system, three-phase, 400 to 1600/4000 kW* * maximum power rating without redundancy 2.5 D. Redundant Power Supply: Each of the three redundant 67kW power converter module shall contain a DC power supply to power the logic and control circuits of each respective 200kW section. Loss of one DC power supply per 200kW section shall not influence the performance of its respective 200kW section. Redundant Power Supplies shall be monitored by the UPS’s internal and optional external monitoring system. E. Redundant UPS Control Power: Two main redundant power supplies shall also be provided for main logic circuits and interface signals of the UPS. These power supplies shall have multiple channels, each with their own overcurrent protection to provide fault containment. Each channel shall have tripped indicators to allow for rapid diagnostics and repair by onsite service personnel. UPS Control Power shall be monitored by the UPS’s internal and optional external monitoring system. F. Redundant Fans: Each 67 kW power module shall contain redundant cooling fans to take in ambient air through filtered inlets on the front of the UPS. The loss of fans in any or all of the 67kW power modules shall not cause a derating of the ambient operating temperature of the UPS. Each 200kW section shall contain four cooling fans and shall operate normally with the failure of any two section fans. All fans shall be monitored by the UPS’s internal and optional external monitoring system for operation and speed. G. Scalability: The UPS shall be designed to allow the 200kW power module sections to be added to accommodate future increases in load requirements to the maximum UPS frame size. H. Proportional Load Sharing: Based upon the modular construction of the system, it shall be possible to parallel UPS’s of different siz