Operators Manual - Always On UPS Systems

Borealis Series

Three Phase ELI System

8 KW – 48 KW

Operators Manual

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 i

NOTE

The instructions contained in this manual are not intended to cover all of the details or variations in equipment, or to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred directly to Always On.

Any electrical or mechanical modifications to this equipment, without prior written consent of Always On, will void all warranties and may void UL/cUL listing. Unauthorized modifications may also result in personal injury, death, and damage to the equipment.

Dear Customer,

Thank you for selecting our emergency lighting inverter (ELI). We are pleased to include you as one of our valued Always On customers!

We are confident that this emergency lighting inverter system, developed and manufactured in our ISO 9001 certified facilities, will provide the quality and satisfaction you demand.

Please read this installation manual carefully as it contains the necessary information required to install the ELI properly.

Thank you for choosing Always On.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 ii

Preface

Congratulations on your choice of our emergency lighting inverter (ELI).

This equipment has been manufactured and tested using methods and procedures equivalent to

UL 924.

This manual describes the recommended procedures for installing the ELI.

While every effort has been made to ensure the completeness and accuracy of this manual,

Always On assumes no responsibility or liability for any losses or damages resulting from the use of the information contained in this document.

WARNING: This manual is intended to provide installation instructions only. The information contained in this manual is to be used as a guideline and recommendation only. Only qualified personnel should perform installation and maintenance. Factory authorized personnel shall inspect installation prior to start up and commissioning to validate warranty.

Failure to follow this directive will void the warranty.

We recommend that this manual be kept with the ELI for future reference. If any problems are encountered with the procedures contained in this manual, please contact our Service

Centre before proceeding.

This document may not be copied or reproduced without the explicit written permission of

Always On.

Due to technical advancements and improvements, some of the information contained in this manual may be changed or modified without prior notice.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 iii

Symbols

The following symbols are used through out this manual.

Warning Information

This symbol alerts you to important information.

Electrical Hazard

This symbol indicates an electrical hazard may be present.

Electrical Symbols

Protective grounding terminal; a terminal that must be connected to ground prior to making any other connection to the equipment.

A terminal to/from which an alternating current or voltage may be applied/supplied.

A terminal to/from which a direct current or voltage may be applied/supplied.

This symbol indicates the word “phase”.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 iv

Safety Instructions

READ AND FOLLOW ALL SAFETY INSTRUCTIONS.

SAVE THESE INSTRUCTIONS.

This manual contains important safety instructions that should be followed during installation and maintenance of the ELI system and optional packages. Before the installation process begins, we recommend that the installer read through the safety precautions, operators manual and the option installation instructions, taking all necessary safety precautions to protect themselves and the equipment being installed.

GENERAL

-

Move the ELI in an upright position, in its original packaging, to its final destination.

-

-

To lift the cabinets, use a forklift or lifting belts with spreader bars.

Check for sufficient floor and elevator loading capacity.

-

-

Check the integrity of the ELI equipment carefully.

If visible damage is evident, do not attempt to install or start the ELI. Contact the transport delivery company immediately, file a claim with the transport company and inform Always On directly.

-

-

-

-

-

-

-

-

-

-

-

Do not use outdoors.

The use of accessory equipment not recommended by Always On may cause an unsafe condition

WARNING! RISK OF ELECTRICAL SHOCK: use extreme caution when removing covers.

All maintenance and service work should be performed by qualified and trained service personnel. The ELI may contain its own energy source, (batteries) which can be dangerous to the untrained person. This ELI contains potentially hazardous voltages

The field-wiring terminals may be electrically live, even when the ELI is not connected to the utility.

Use caution when servicing batteries. A battery can present a risk of electrical shock, burn from high short-current. Battery acid can cause burns to skin and eyes. If acid is spilled on skin or in eyes, flush with fresh water and contact physician immediately.

When replacing batteries use the same number and type (sealed-cell lead acid).

Proper disposal of batteries is required. Refer to your local codes for disposal requirements.

Dangerous voltages may be present during battery operation. The batteries must be disconnected during maintenance or service work. (Open battery breaker or fuses)

Be aware that the inverter can restart automatically after the utility voltage is restored.

Do not use this equipment for other than intended use.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 v

INSTALLATION

-

-

-

This ELI is intended for use in a controlled indoor environment free of conductive contaminants and protected against any type of intrusion.

Do not install the ELI in an excessively humid environment or near water.

Avoid spilling liquids and/or dropping any foreign object(s) onto the ELI.

-

-

-

-

The unit must be placed in a sufficiently ventilated area; the ambient temperature should not exceed 40°C (104°F).

Optimal battery life is obtained if the ambient temperature does not exceed 25°C (77°F).

HIGH GROUND LEAKAGE CURRENT: ground connection completed before connecting the AC voltage wires on the input!

Switching OFF the ELI does not isolate the ELI from the utility as the utility supply is still

HOT at the input terminal strip. Supply breaker needs to be opened.

It is important that air can move freely around and through the unit. Do not block the air

- vents.

Avoid locations in direct sunlight or near heat sources (gas or electric heaters).

-

STORAGE

-

-

-

Store the ELI in a dry location free of contaminants;

Storage temperature must be within -25°C (-13°F) to 55°C (131°F).

If the unit is stored for a period exceeding 3 months, the batteries must be recharged periodically (time depending on storage temperature).

WARNING!

LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT IS

APPARENTLY NOT OPERATING. OBSERVE ALL CAUTIONS AND WARNINGS IN THIS

MANUAL. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

REFER UNIT TO QUALIFIED SERVICE PERSONNEL IF MAINTENANCE IS REQUIRED.

NO ONE SHOULD WORK ON THIS EQUIPMENT UNLESS THEY ARE FULLY

QUALIFIED TO DO SO. AN INSTALLER SHOULD NEVER WORK ALONE.

WARNING!

WHEN REMOVING POWER FROM THE ELI, ALLOW FIVE MINUTES FOR

CAPACITORS TO DISCHARGE BEFORE WORKING ON THE EQUIPMENT.

CAUTION!

This equipment complies with the requirements in Part 15 of FCC rules for a Class A computing device. Operation of this equipment in a residential area may cause interference to radio and TV reception, requiring the operator to take whatever steps necessary to correct the interference.

CAUTION!

Do not put option control wiring in the same conduit as the ELI input or output power cables.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 vi

THIS SAFETY NOTICE IS ADDRESSED TO THE ALWAYS ON

CUSTOMER ENGINEERS WHO PERFORM MAINTENANCE OF THE

UNINTERRUPTIBLE POWER SUPPLY (ELI) SYSTEMS.

Electrical Safety

• Maintenance work to be performed by a factory trained customer engineers, or qualified personnel. Extremely dangerous voltage levels can exist within the ELI system. Extreme caution must be used.

• Ensure system is in maintenance bypass mode or external wrap-around bypass mode before work is started.

• This manual is designed as an aid tool in diagnosing problems that may arise.

Always On does not assume responsibility if information causes injuries.

• Apart from the front door, do not open any other part of the ELI without consulting the factory first. Before removing the protection screens, be sure that the unit is completely powered off.

• Be aware that dangerous voltage can be supplied by the internal battery or electrolytic capacitors.

• When system is in bypass mode and all fuses have been opened dangerous voltages may exist within the ELI system. Use extreme caution when exchanging boards and working inside the unit.

READ AND FOLLOW ALL SAFETY INSTRUCTIONS.

SAVE THESE INSTRUCTIONS.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 vii

TABLE OF CONTENTS

1 Introduction ........................................................................................................................................................... 1

1.1

Overview ............................................................................................................................................................................... 1

1.2

Features ................................................................................................................................................................................ 1

1.3

Definitions ............................................................................................................................................................................ 2

2 Theory of Operation............................................................................................................................................. 3

2.1

General Topology ............................................................................................................................................................... 3

2.2

Normal Operation Mode ................................................................................................................................................... 4

2.3

Backup Mode ...................................................................................................................................................................... 4

2.4

Reserve Mode ..................................................................................................................................................................... 5

2.5

Manual Bypass Mode ........................................................................................................................................................ 5

2.6

Features and Advantages ................................................................................................................................................ 6

2.7

Rectifier ................................................................................................................................................................................ 8

2.8

Inverter .................................................................................................................................................................................. 9

2.9

Static Switch .......................................................................................................................................................................10

2.10

Manual Bypass Switch .....................................................................................................................................................10

3 Inter-PCB Diagram ............................................................................................................................................. 12

4 Physical Topology ............................................................................................................................................. 13

5 Installation ........................................................................................................................................................... 16

5.1

Site & Environmental Conditions ..................................................................................................................................16

5.2

Cable Selection ..................................................................................................................................................................18

5.3

Terminal Strip Connections ............................................................................................................................................19

6 Front Panel ........................................................................................................................................................... 20

7 Operation .............................................................................................................................................................. 25

7.1

Switch On Procedure (Authorized Trained Personnel Only) .................................................................................25

7.2

Shutdown Procedure .......................................................................................................................................................26

7.3

From Inverter To Manual Bypass Procedure .............................................................................................................27

7.4

From Manual Bypass to Inverter Procedure ..............................................................................................................28

7.5

Manual Battery Test ..........................................................................................................................................................28

7.6

Battery Condition Test .....................................................................................................................................................28

8 The LCD Display ................................................................................................................................................. 29

8.1

Menu 0 – Main Menu .........................................................................................................................................................29

8.2

Menu 1 – Select Menu ......................................................................................................................................................30

8.3

Menu 2 – Status Warning Menu .....................................................................................................................................30

8.4

Menu 3 – Real Time Data Menu .....................................................................................................................................32

8.5

Menu 4 – Historical Event Menu ....................................................................................................................................34

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 viii

9 INTERFACE CONNECTIONS ........................................................................................................................... 36

9.1

Dry Contacts .......................................................................................................................................................................36

9.2

Software for PC Monitoring ............................................................................................................................................37

9.3

Emergency Power off Connection ................................................................................................................................37

9.4

DB9 Connectors ................................................................................................................................................................37

9.5

Web Monitoring Module (SNMP Module) ....................................................................................................................37

9.6

Emergency Lighting Notification ..................................................................................................................................38

10 Battery Backup Units (BBU) ............................................................................................................................ 39

10.1

Run Time Charts ................................................................................................................................................................41

10.2

BBU Configurations .........................................................................................................................................................43

11 Options ................................................................................................................................................................. 45

11.1

Emergency Stop Switch ..................................................................................................................................................45

11.2

Remote Display Panel ......................................................................................................................................................45

11.3

12 Pulse Rectifier ..............................................................................................................................................................45

11.4

External Wrap Around Bypass ......................................................................................................................................45

11.5

Normally Off Function ......................................................................................................................................................45

12 Technical Specifications .................................................................................................................................. 46

13 Contact Information ........................................................................................................................................... 50

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 ix

1 Introduction

Congratulations on your choice of the Borealis On-Line Emergency Lighting Inverter (ELI).

This ELI features the latest top of the line microprocessor technology and IGBT transistors and provides clean, highly regulated and pulse width modulated (PWM) true sine wave power.

1.1 Overview

This ELI is designed for installation between your AC power supply (utility or generator) and your lighting equipment. It provides power to your equipment during major power events such as blackouts and brownouts, over-voltage and undervoltage conditions. The ELI provides a consistent supply of regulated AC power during these power events, allowing you to ensure safety and lighting for the period required.

1.2 Features

This ELI provides full time self-diagnostics as well as two levels of audible alarms when the unit is operating in battery mode. Along with the current mode of operation, the LCD screen displays critical system information including:

• Percent

Remaining battery capacity, battery voltage voltage, voltage, frequency,

Output frequency and

Internal ELI temperature.

A manual test switch has been incorporated into the input/test breaker that makes testing a simple procedure. The internal bypass switch allows maintenance on the

ELI to be performed without interruption of power to the load.

The communications port, in conjunction with multi-platform monitoring and control software, enables the unit to be connected to a local or networked computer system.

Detailed operating information including voltages, currents, and alarm status is available to the monitoring system.

Other communications options include:

An SNMP adapter to remotely control and monitor the unit via a network or the Internet.

An AS-400 interface to allow for relay communications in PLC or dry contact environments.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 1

1.3 Definitions

Critical Load

These are loads that require clean, regulated and continuous AC power and which are connected to the output of the ELI module

ELI Module

The portion of the ELI system that contains one or more of: the rectifier /

DFC, charger, inverter, static bypass switch, maintenance bypass switch, controls, monitoring, and indicators.

Rectifier / DFC

Contained in the ELI module. Responsible for converting the normal AC input power to DC power and supplying the inverter with DC power.

Charger

Contained in the ELI module. Responsible for recharging the batteries.

Inverter

Contained in the ELI module. Responsible for converting DC power (supplied by the rectifier) to regulated and filtered AC power that is then supplied to the critical loads.

Static Bypass Switch

Contained in the ELI module. Responsible for automatically transferring the attached load, without interruption, from the inverter AC output to the bypass

AC power source in the event of an overload or degradation of the inverter’s performance.

Maintenance Bypass Switch:

Contained in the ELI module. Used to transferring the attached load, without interruption, from the inverter AC output to the bypass AC power source while electrically isolating the static bypass switch, rectifier / DFC, charger and inverter. Used for maintenance purposes.

Battery

The battery system provides DC power to the inverter input when the normal

AC input power to the ELI fails.

IGBT

Isolated Gate Bipolar Transistor.

PWM

Pulse Width Modulation.

ELI

Emergency Lighting Inverter.

BBU

Battery Backup Unit.

PFC

Power Factor Correction.

EPO

Emergency Power Off.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 2

2 Theory of Operation

Figure 2.1

General Block Diagram

ELI Module Components: The ELI module consists of the following major components:

-

Input, Reserve and Bypass circuit breakers

-

Rectifier / Charger

- Inverter

-

Microprocessor controlled logic and control panel with alarm indicators and digital metering display

-

External battery connection

- Static

-

Full maintenance bypass

-

Emergency power off (EPO) connection

-

SNMP Adapter for network communications and monitoring

-

Input power walk-in

-

Output isolation transformer

-

12-pulse rectifier and harmonic filter to reduce input harmonic content.

-

Additional battery modules for extended runtime

-

Top cable entry

-

Remote display panel

-

Emergency power off switch

-

External maintenance bypass cabinet

-

Isolated parallel redundant operation (IPRO)

Generally, there are four modes of operation for an ELI system, NORMAL MODE,

BACK-UP (BATTERY) MODE, RESERVE MODE and MAINTENANCE BYPASS

MODE.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 3

2.2

Normal Operation Mode

Figure 2.2

Normal Mode Operation

The rectifier/charger converts the supplied AC power into DC (bus) power that is then supplied to the inverter and the battery charger. The DC to AC inverter then supplies continuous, noise free AC power to the critical loads. The inverter output is synchronized with the bypass AC power source provided that the bypass AC power source is within the specified frequency range.

Backup Mode

2.3

Figure 2.3

Back-up Mode Operation

As the batteries are connected to the DC bus they supply energy to the inverter via this DC bus, the AC power will remain constant and continuous without interruption to the loads when the AC fails or falls out side of the operating parameters. Upon return of the supplied AC input power the ELI. The rectifier will automatically assume the DC load (charger, inverter) from the batteries. The ELI will simultaneously supply power to the inverter and the battery charger to replenish the batteries.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 4

2.5

2.4

Reserve Mode

Figure 2.4

Reserve Mode Operation

If the inverter is placed into an abnormal condition, such as over temperature, short circuit, abnormal output voltage or is overloaded for a period which exceeds the inverter’s limits, the inverter will automatically shutdown in order to protect itself. If the AC utility power is within the normal parameters, the static switch will automatically transfer the load to the reserve (utility) source without interruption of the AC output.

Manual Bypass Mode

Figure 2.5

Manual Bypass Mode Operation

During ELI service procedures or battery replacement, the loads cannot be interrupted, and as such the technician needs to turn off the inverter switch, close the bypass breaker and then open the rectifier and reserve (utility) breakers. The

ELI is now running in Manual By-pass mode supplying utility AC to the loads. The

AC output will not be interrupted during the manual bypass transfer procedure because the manual bypass switch is designed to supply continuous power to the loads.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 5

2.6

Features and Advantages

a. Reliable input protection: Circuit breakers are in each input loop to ensure power can continue through the other loops in the event of a breaker trip caused by abnormal conditions in either the rectifier or the load.

b. Input surge protection: Input surge protection is added at the input to provide enhanced protection to both the ELI and the load and also protects against lightning effects and/or surges caused by large cycling loads or those that are being turned on and/or off.

c. EMI suppression: An EMI filter is added to meet the international EMC limits to ensure that No noise will effect or interfere with other equipment connected to the same AC source.

d. Ruggedness: The rectifier employs phase control technology to regulate the

DC bus voltage allowing the batteries to be charged while supplying DC power to the inverter. This has been proven to be the most efficient method to control and regulate the charge on the batteries. The SCR technology and

PFC circuit also assist in maintaining the input waveform.

e. High frequency design: The inverter design incorporates high frequency, highly efficiency Insulated Gate Bi-polar Transistors (IGBT). A PWM wave, synchronized to the bypass input, triggers the IGBT’s, which invert the DC into AC power required by the loads. This design decreases the number of required components, increases reliability and performance while decreasing acoustic noise, size and weight.

f. True galvanic isolation: The isolation transformer addresses ground differentials between the input and output, and prevents ground leakage current problems, common mode and normal mode noise. This transformer is located on the output side of the ELI system providing isolation under every mode of operation.

g. PNP modular design: The circuit boards are designed into several modules, which are plugged into slots in the ELI. These plug-able modules allow for easy replacement in the field when necessary and eliminate field diagnostics.

h. Cold start function: The ELI can be started without the utility AC supply being activated. Or present at the input terminal strip because our designed system is designed with current limiting circuitry, which allows Startup of the

ELI on battery DC power.

i. Multi-CPU design: Several CPU’s are designed into the control circuit.

These critical functions are designed with multi-level redundancy increasing reliability and up-times by eliminating field problems.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 6

j. Protection against possible operator error: The ELI is designed with breaker on/off sensors and power supply sensors. These sensors prevent potential operational mistakes from interfering with the start –up operation causing possible damage.

k. Wide input range: The components are overrated by design to handle high input voltages and currents without harm to the system, ensuring that Always

On ELI’s remain one of the most reliable ELI Systems available in today’s market. degree of safety margins allowing for wider environmental parameters and specifications related to temperature, humidity, altitude, surge or noise.

m. Intelligent charger: The ELI will automatically recharge (boost charge) the batteries when the battery voltage level decreases to approximately 2V/Cell or to a user specified level. To prevent the over-charging of the battery, the boost charge will stop when batteries achieve a 90% charged level or the ambient temperature reaches 35 o

C (95 o

F) at which point the float charging begins.

n. Intelligent battery test: The batteries are tested after every boost charge whether the charge has been initiated by a battery discharge state (2V/Cell) or by the regular battery test performed by the ELI (monthly test). When an abnormal condition (low charge rating, or bad battery) is found the user will be informed immediately through alarms on the ELI system.

o. Charging rate: The charging rate is selectable (L/M/H) according to Ah ratings of the batteries. The charger is designed to charge the larger battery banks without adding an additional charger (up to 8hr. back-up).

p. MTBF of cooling fans: Long cycling fans will operate at variable speeds necessary which is dependent on the ambient temperature of the ELI system increasing the life expectancy of the fan motors.

q. Redundant power supply: Redundant power supplies have been installed to allow for worry free operation of the system. control up to ninety-nine ELI’s. The communication allows for N+1 redundancy, whereby if one system encounters an emergency or fault condition, it will warn the user immediately and the load is automatically transferred to the other ELI systems. The ELI status, data or commands are transmitted to external modules through four RS-485 ports.

s. Data log capability: All abnormal conditions will be stored within the ELI control interface board for further reference by the user. Each abnormal condition is time and date stamped (real-time clock) as the event occurs. This history is stored and cannot be removed even if or when the ELI is turned off for servicing.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 7

2.7

t. Convenient front panel design: The LCD display and control switches are accessible through the up, down, and enter switches below the front panel window. All the viewable parameters can be read without opening the front door. The inverter on/off switch is protected from accidental operation by being located behind the locked front door although the inverter can still be switched on and off via the control switches on the front panel but this feature is password protected.

u. Emergency stop: In the event of an emergency the ELI can be shutdown

(no AC at the output) either through a switch (optional) or through a smoke detector signal (optional).

Rectifier

The main function of a rectifier is to convert the AC input power to DC power. The

DC power is then used to charge the batteries, supply the DC bus, which in turn supplies the inverter.

Figure 2.6

Rectifier Function

The rectifier design used in the 8KW to 48KW ELI’s include a 6-pulse full controlled rectifier. Power Factor Correction (PFC) has been added to maintain a high input power factor, independent of the load power factor. This 6 pulse rectifier smoothes the current waveform and reduces the harmonic content reflected back to the utility. The control circuit regulates the DC bus to within 1% of the nominal voltage. Soft walk-in circuitry (approximately 20 seconds) and current limiting circuitry are used to prevent over current or surge currents from affecting any part of the ELI system.

Additionally, over and under-voltage protection is added to improve reliability and to shutdown the rectifier in the event of abnormal conditions. The DC bus is adjustable to allow for different types and capacities of batteries. The power components used within the rectifier are specially designed and selected to handle extreme ranges of high voltage and high current (–25% to +25%).

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 8

2.8

Inverter

Figure 2.7

Inverter Layout

The inverter is composed of IGBT’s, inductors, capacitors, highly efficient filters, control circuitry and protection circuitry. This inverter inverts the DC power received on the DC bus to isolated, noise-free AC power, which is then supplied to the critical loads. Our PWM wave generator is switching at a higher frequency well above the human audible range.

The Voltage regulating circuitry limits the output voltage variation to within 1% of the nominal voltage and special compensation circuitry has been added to eliminate output distortion. Every component is oversized to accept a wide DC input range (from 285 to 420VDC), allowing the output waveform to remain sinusoidal throughout the entire range. With the aid of dynamic feedback loop circuits the inverter maintains a true sine wave output, even if non-linear loads are connected.

The system is designed to incorporate an independent inverter per phase. These inverters are totally independent of each other preventing the possibility of cascading failures. This allows the user to connect loads to adjacent inverters without affecting the other inverters providing high-end voltage regulation under a

100% unbalanced load situation.

The IGBT is operated in its optimal condition to obtain maximum efficiency, keeping electrical costs to a minimum.

Usually, most ELI failures are a result of inverter failures. To prevent this occurrence, Always On has included redundant protection circuitry to protect the inverter and increase its reliability. To enhance this protection we have also added a high efficiency filter designed to suppress the spikes and noise that can be reflected from the attached loads back into the ELI system. Specifying oversized and high quality components, additional semi-conductor fuses and allowing for good ventilation systems within further increase reliability.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 9

Figure 2.8

Static Bypass

The static switch is composed of two pairs of back to back naturally commutated

SCR’s, which moves the load from inverter to reserve (utility) or from reserve to inverter without interruption of power to the load.

Detection circuitry is included in the control circuit to achieve “0” dead time transfer. Additional detection is employed to control the static switch transfer.

Dead Short: If a dead short circuit was to occur under normal mode operation, the ELI would detect the short circuit and immediately stop the inverter until the problem has been rectified. Due to the large amount of current a dead short requires, the static switch will not transfer to reserve preventing the tripping of the reserve breaker.

Overload condition: The ELI will transfer the load to reserve (utility) path. The static switch is designed to handle 110% of the capacity of the system, but will switch to the reserve path if the overload continues for the specified length of time. The load will be operational, but in the event of a utility failure the inverter has been shutdown therefore no battery time is available until the overload is removed and inverter is allowed to reset.

The static switch will only be activated if the input levels are within parameters to ensure the load is only supplied with acceptable power to protect against damage that may be caused to the critical load. The system performs numerous checks on the transfer from inverter to bypass and visa versa to ensure the exchange is smooth.

2.10

Manual Bypass Switch

The manual bypass switch is a function of Always On ELI’s that is open under normal operation, and closed for service. All power supplied to the ELI should be disconnected before service begins. The manual bypass is switched seamlessly to supply utility AC power to the loads during ELI servicing. If the bypass breaker is closed (by mistake) under normal operations, the inverter will stop and the load will be transferred to reserve (utility) power.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 10

The inverter cannot be turned on when the maintenance bypass breaker is in the closed position.

(The operation of the manual bypass breaker is explained later in this manual)

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 11

LCD

Switch

LED

Dry

Contact

3 Inter-PCB Diagram

12 Pulse Rectifier

Rectifier

Driver

Rectifier

Control

Rectifier

Driver

Rectifier

Control

6 Pulse Rectifier

Power Supply

Controller

Batt

Relay

Display

Call

Service

Remote Control

Panel

PC

Communications

SNMP (Web)

Monitoring

Battery Monitoring

Optional Communication

Features

Figure 3.1

Block Diagram for Component and Feature Layout

SS Drive

R Phase

S Phase

T Phase

Inverter

Driver

Inverter

Driver

Inverter

Driver

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 12

4 Physical Topology

WARNING

Dangerous AC & DCPHIGH

VOLTAGE !

Operating Proc edure

Wa rning: For Installation & First Time Startup, Plea se Se

Startup Proc edure

1. Close the INPUT brea ker.P2. Close the RESERVE breaker.P3. C lose the REC TIFIER brea ker.P4. Wait 30 sec ound for the DC bus P v oltage to rise .The warning

LEDsP "BAT LOW" a nd 'BAT LOW STOP"P on the front pa nel will turn off.P5. C lose the BATTERY breaker/P

fuses.P6. Start the INVERTER module b yP pressing &

on the LCD panelP sim ultaniously.P7. The load will transfer to inverterP outp ut in ap proxima te ly 7 sec onds.P8. Loc k the door.

Shutdown Proc edure

1. Turn off the INVERTER m odule byP pressing &

on the LCD panelP sim ultaniousl y.P2. Open the

BATTERY breaker/P fuses.P3. Open the RECTIFIER breaker.P4. Wait 5 minutes fo r DC Pcap acitor to discharge.P5. Open the RESERVE breaker. P6. Open the INPUT b rea ke r. P7. Loc k the door.

1. Turn off the INVERTER m odule byP pressing &

on the LCD panelP sim ultaniously.P2. Open the breaker.P4. Wait 5 minutes fo r DC capa citorsP to discharge.P5. Close the bypass b rea ke r. P6. Open the Reserve b re aker. P7. The UPS is now in manual byp ass.

Inverter to Manual Bypa ss Proced ure Manual Bypass to Inve rterP Procedure

1. Close all fuses behind the c ontrolP module door.P2.

Close the RESERVE breaker.P3. Op en the Bypass breakerP4. Clo se the RECTIFIER breaker.P5. Wait 30 seconds for the DC bus P voltage to rise .The warning

LEDsP "BAT LOW" a nd 'BAT LOW STOP"P on the front pa nel will turn off.P6. C lose the BATTERY breaker/P

fuses.P7. Start the INVERTER module b yP pressing &

on the LCD panelP sim ultaniously.P8. The load will transfer to inverterP outp ut in ap proxima te ly 7 seconds.P9. Lock the door.

Before Maintenance beginsPOn UPS

1. Open all fuses behind the c ontrolP m odule doo r.

INPUT RECTIFIER RESERVE BYPASS

Figure 4.1

Front view of system with

Door Closed

ELI Rating

(KW) W (Width)

8

12

16

24

32

40

48

Dimensions

D (Depth)

559mm (22")

559mm (22")

559mm (22")

815mm (32.0")

815mm (32.0")

815mm (32.0")

559mm (22")

559mm (22")

815mm (32.0")

815mm (32.0")

559mm (22") 815mm (32.0")

1,100mm (43.25") 815mm (32.0")

Figure 4.2

Front view of system with Door Open

H (Height)

1,600mm (63.0")

1,600mm (63.0")

1,600mm (63.0")

1,600mm (63.0")

1,600mm (63.0")

1,600mm (63.0")

1,600mm (63.0")

ELI

380kg (838lbs)

415kg (915lbs)

450kg (992lbs)

580kg (1,279lbs)

650kg (1,433lbs)

710kg (1,565lbs)

920kg (2,024lbs)

Weight

Floor Loading

864 kg/sq.m (177 lbs/sq.ft.)

943 kg/sq.m (193 lbs/sq.ft)

1,023 kg/sq.m (210 lbs/sq.ft)

1,318 kg/sq.m (270 lbs/sq.ft.)

1,477 kg/sq.m (303 lbs/sq.ft.)

1,614 kg/sq.m (330 lbs/sq.ft)

1,672 kg/sq.m (207 lbs.sq.ft.)

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 13

CAP

CAP

CAP

AC

PS

SS

PS

O/P

R

O/P O/P

S T

IN IR IS IT OR OS OT ON B+ B-

CNC1 CNB1 CNB2 CNB7

LCD PANEL

3C

RECTIFIER CONTROL

R

R G

CNC3

TO REC.

MODULE

CNC4

CNA4

R

R

R

R

CNA8

TO S.S.

MODULE

3A

MAIN CONTROL

G

Y

3B

POWER SUPPLY

G R

CNB6

R

G

CNA7

CNA9 CNA10

R

G

CNA11

CNT2 CNT2 CNT2

RED WHT B LU

3T

INVERTER PHASE

CONTROL

(R PHASE)

3T

INVERTER PHASE

CONTROL

(S PHASE)

CNT3 CNT4 R G CNT3 CNT4 R G

3T

INVERTER PHASE

CONTROL

(T PHASE)

TO INV.

MODULE

CNT3 CNT4 R G

WARNING

LED PANEL

& SWITCHES

MIMIC PANEL

STATUS

LED PANEL

& BEEPER

CNR4 CNR1

R

3R

COMMUNICATIONS

INTERFACE

RS232 RS485

CNR7

RELAY INTERFACE

Figure 4.3

Front view of system with Door

Open, PCB Module fully open and terminal strip cover off

Figure 4.4

Front view of system with Door

Open and PCB Module door open

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 14

559mm [22”]

Figure 4.5

Front, Side & Top Views of the System

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 15

5 Installation

5.1 Site & Environmental Conditions

The designed function of the ELI is to provide a safe, clean and independent electrical supply free from random variations, disturbances or interruptions of the utility mains. The ELI will provide a constant power source, which is regulated in both voltage and frequency. When the utility mains are not available, the ELI will provide optimal back-up time depending on the capacity connected battery bank.

Usually the life expectancy of the ELI is 8 to 10 years. The optimal life expectancy of the ELI can be achieved by careful consideration of the site and environment.

The following precautions and recommendations should be checked when considering the site and environment for the ELI:

a. The ELI should be located in a place with adequate ventilation (refer to the specification of the heat dissipation of the ELI). Should the ELI be installed in a sealed room, care must be taken to ensure adequate heat evacuation is provided.

34

"

52"

25"

35"

2'

3'

Figure 5.1

Minimum Spacing Requirements

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 16

b. Void space is not required on all sides of the ELI system, but adequate space, a minimum of 1m (3’), should be allowed for the door to open. Adequate space, a minimum of 60cm (2’) [recommended 1m (3’)], should also be allowed at the top of the ELI system to allow for proper heat dissipation and ventilated through the top openings (optional ventilation booth is available upon request).

Leave a minimum of 2 feet on right hand side of ELI.

c. The battery banks require access to front only.

d. Do not place any objects on the top of the ELI that might obscure the ventilation. Do not place the ELI near any heat source, or machinery, which may produce metallic particles, dust or powder. Do not place the ELI near equipment that will produce corrosive substances or vapor.

e. Do not place the ELI below the shower of a fire extinguishing system

(optional drip shield available). Abnormal conditions of the ELI should be protected by a cutoff from the power supply.

f. The user is required to guarantee the temperature and humidity values of the site into which the ELI will be installed meet the required and published manufacturer specifications. The ELI should be installed within the range allowed by these specifications. The ELI is capable of continuous normal operation within a temperature range of 0°C (32°F) to 40°C (104°F). For optimal performance and reliability the recommended environment temperature is best at 25°C, with humidity 0 to 95% non-condensing.

g. The floor loading capacity should be sufficient to endure the weight of the

ELI. Four right-angled steel feet attached restrainers are included with the ELI system, which should be inserted into the floor for securing the ELI system, when the location has the potential to experience vibrations. (e.g.: earthquake, moving vehicles, or tanker.) The locations and layout of the restrainers are shown below.

h. Walls, ceilings, floors or anything near to the ELI should be constructed of non-combustible materials. A portable fire extinguisher should be accessible nearby.

i. Avoid accumulating litter or trash of any sort in or around the ELI system.

The floor area surrounding the ELI should be kept clean, free from metallic powder and/or filings.

j. Access to the ELI room should be limited to operation and maintenance personnel. The doors should be kept locked and the keys should be available only to authorized personnel.

k. Personnel who operate or maintain the ELI system should be proficient in normal and emergency operational procedures. New personnel should be trained and qualified prior to operation of the equipment.

l. Although the ELI has passed the international EMC tests, it is not recommended to install the ELI near to any equipment that is susceptible to

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 17

electro-magnetic interference, such as computer systems, monitors, radios etc.

m.

The system should be connected to the emergency generator, if available.

n.

The system, when installed in a sprinkler-equipped room, must have a sprinkler guard installed.

The cabling of the ELI system has to be sized according to the ELI power rating.

Sizing of circuit breakers, fuses and cables for input utility, output load and battery must meet the requirements of local and national electrical codes.

Refer to Section 10 for technical specifications.

WARNING

Inadequate cable size and over sized breakers can increase the risk of fire or damage connection cables and internal components.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 18

5.3 Terminal Strip Connections

RECTIFIER & RESERVE

INPUT

ELI

OUTPUT

BATTERY

INPUT

IN IR IS IT OR OS OT ON B+ BG

FIRE ALARM

CONNECTION

N

WHITE

LINE

1

RED

LINE

2

BLACK

LINE

3

BLUE

LINE

1

RED

LINE

2

BLACK

LINE

3

BLUE

N

BAT

+

RED

BAT

-

BLACK WHITE

3 PHASE INPUT / 3 PHASE OUTPUT

G

GREEN

TERMINAL WITH SINGLE SOURCE

* CAUTION: REMOVE THE NEUTRAL BONDING JUMPER IF ELI IS CONNECTED TO AN

EXTERNAL BYPASS SYSTEM.

RECTIFIER & RESERVE

INPUT

ELI

OUTPUT

BATTERY

INPUT

FIRE ALARM

CONNECTION

IN IR IS IT OR OS

OT

ON

B+ B-

G

*

3 PHASE INPUT / 3 PHASE OUTPUT

TERMINAL WITH SINGLE SOURCE

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 19

F

G

H

A

6 Front Panel

E

BYPASS

RESERVE

RECTIFIER

BATTERY

INVERTER

RESERVE

STATIC SWITCH

INVERTER

STATIC SWITCH

L

OUTPUT

B

WARNING

RECT AC FAIL

RES AC FAIL

FUSE/TEMP

OVERLOAD

HIGH DC

BAT LOW

BAT LOW STOP

FAULT

INVERTER CONTROLS

ON OFF

LCD CONTROLS

UP

DOWN ENTER

J P Q M N O R

Figure 6.1

Front Panel Display

The front panel is located behind the glass window on the front of the ELI system. It displays the real time information and status of the ELI and battery system. It also provides for user interface for controlling and setting the ELI operating status. This panel also allows the user to operate and monitor the system with ease. The panel is explained below:

A: LCD display- Real time status, data and historical events are displayed on the LCD.

The ELI parameters, real time clock, inverter, and buzzer can also be set through this LCD. The LCD is back lit by LED’s for a sharper display, but in order to lengthen the LED’s life time, the LED will automatically shut off 3 minutes after a key has been pressed, and will light up again when one of the up/down/enter keys are pushed.

C

INVERTER ON

INV STATIC

SWITCH ON

OUTPUT

SHORT CIRCUIT

FUSE/TEMP

INV SHUTDOWN

INVERTER FAIL

INV SHUTDOWN

BYPASS ON

INV SHUTDOWN

HIGH DC BUSS

INV SHUTDOWN

INV OVERLOAD

INV SHUTDOWN

70% LOAD

110% LOAD

125% LOAD

150% LOAD

STATUS

RESERVE

AC FAIL

RESERVE

FREQ FAIL

BATTERY LOW

BATTERY LOW

SHUTDOWN

RECTIFIER

AC FAIL

Ø ROTATION

ERROR

RECTIFIER

SHUTDOWN

RECTIFIER

HIGH DC

BOOST

CHARGE

BATTERY

TEST

EMERGENCY

STOP

COMM.

ACTIVE

D

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 20

B: Warning LED’s-When an abnormal condition occurs, these LED’s will illuminate allowing the user to identify the fault. This will also allow the service personnel the ability to troubleshoot the system. These LED’s are described below:

RECT AC FAIL – when the supply to the rectifier is outside of the operating parameters. This not only applies to voltage range but also when phase rotation is incorrect or the rectifier has been shutdown

(refer to C: Status LED’s).

RES AC FAIL – supply to the reserve is outside of the operating parameters. Supply voltage or frequency out of range (refer to C:

Status LED’s).

FUSE/TEMP – inverter has shutdown due to inverter fuse open or heat sink temperature above operating parameters.

OVERLOAD – an overload condition has occurred on the output.

HIGH DC – this LED will be lit as long as the DC voltage exceeds

430VDC.

BAT LOW – this LED will be lit as long as the DC voltage is lower than 320VDC.

BAT LOW STOP – the LED will be lit as long as the DC voltage is lower than 295VDC. The inverter will not activate until the DC voltage is above this level.

FAULT – the inverter has shutdown because an abnormal condition has occurred. Possible conditions include overload, short circuit, high

DC shutdown, fuse/over temperature, bypass breaker on or emergency stop (refer to C: Status LED’s).

C: Status LED’s- 24 LED’s represent the real-time information regarding the status of the ELI system. These LED’s will aid in diagnosing and trouble shooting abnormal conditions. The 24 LED’s represent the following:

INVERTER ON – inverter is running.

INV STATIC SWITCH ON – inverter static switch is active.

OUTPUT SHORT CIRCUIT – ELI output is in a short circuit state.

FUSE/TEMP INV SHUTDOWN – inverter has shutdown due to inverter fuse open or heat sink temperature above operating parameters.

INVERTER FAIL INV SHUTDOWN – inverter has shutdown due to inverter output voltage below tolerances.

BYPASS ON INV SHUTDOWN – inverter has shutdown because the bypass breaker has been activated while the inverter is supplying power to the load.

HIGH DC BUSS INV SHUTDOWN – inverter has shutdown because the DC Bus voltage is outside of operating parameters while the inverter is operating.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 21

INV OVERLOAD INV SHUTDOWN – inverter has shutdown because an overload condition has been detected on the output. The inverter will automatically restart after the condition has been removed for a period of seven seconds.

70% LOAD – load connected to the output is over 70% of the ELI rating.

110% LOAD - load connected to the output is over 110% of the ELI rating.

125% LOAD - load connected to the output is over 125% of the ELI rating.

150% LOAD - load connected to the output is over 150% of the ELI rating.

RESERVE AC FAIL – supply voltage to the Reserve is outside of operating window.

RESERVE FREQ FAIL – supply frequency to the Reserve is outside of operating window.

BATTERY LOW – the DC bus (or battery) voltage is lower than

320VDC. Low battery shutdown is approaching.

BATTERY LOW SHUTDOWN – the inverter has shutdown because the DC bus (or battery) voltage is below operating level (lower than

295VDC).

RECTIFIER AC FAIL – supply to rectifier is outside of operating window.

Ø ROTATION ERROR – supply phase rotation is outside of operating window.

RECTIFIER SHUTDOWN – the rectifier has shutdown because the

DC bus voltage has exceeded maximum operating level (over

445VDC). The rectifier will automatically restart 30 seconds this abnormal condition has been cleared.

RECTIFIER HIGH DC – the DC voltage has exceeded maximum operating level (over 430VDC). The bus voltage is limited to this voltage.

BOOST CHARGE – the batteries are being boost charged by the rectifier.

BATTERY TEST – batteries are being tested.

EMERGENCY STOP – the inverter has shutdown because the emergency stop switch has been activated.

COMM. ACTIVE – blinks when data is being transmitted or received via the communication port.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 22

D: Buzzer outlet:

There is a buzzer located behind the LCD Display. The buzzer will allow for audile notification during an abnormal condition. The buzzer will be activated under one of the following conditions: (The frequency of the buzzer is also described for your reference.)

INVERTER IS OVERLOADED

>110%, beep once / 3 seconds

>125%, beep once / second

>150%, beep twice / second

BACK-UP

>320VDC, beep once /

3seconds

<320VDC, beep twice / second

<295VDC, no beeping

INVERTER IS SHORT CIRCUITED

FUSE BROKEN beep continuously beep continuously

HEAT SINK OVER TEMPERATURE beep

HIGH DC SHUTDOWN beep continuously

BYPASS ON STOP beep continuously continuously

The buzzer will beep once every time the inverter is switched on or off. This will allow for the user to be sure the operation was performed correctly.

E. Bypass LED: This LED is lit when the maintenance bypass breaker is closed leaving the inverter in the off mode. If the inverter is active when the bypass breaker is closed the inverter will shutdown immediately.

F. Reserve LED: This LED is lit when the reserve breaker is closed, and the supply is within operating parameters.

G. Rectifier LED: This LED is lit when the rectifier is operating, the supply is within operating parameters, the rectifier breaker is closed and the DC bus voltage is within operating parameters.

H. Battery LED: This LED is lit while the ELI is in back-up mode. This LED also indicates the results of battery test. If the battery pack does not pass the test, this LED will flash prompting the user to change the battery pack.

I. Inverter LED: This LED is lit when the inverter is supplying power to the load.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 23

J. Inverter Static Switch LED: This LED is lit when the inverter static switch is operating and the reserve static switch is turned off. When this LED is on, the load is supplied from the inverter. Usually this LED will stay lit for 7sec. after the inverter is switched on.

K. Reserve Static Switch LED: This LED is lit when the reserve static switch is operating and the inverter static switch is turned off. When this LED is on, the load is being supplied by the reserve. Since the reserve static switch and inverter static switch will never operate simultaneously, the Inv Static Switch On LED and the Reserve Static

Switch LED will never be lit at the same time.

L. Output LED: This LED is lit when there is AC power present at the output terminals.

M. Up key:

This is an LCD control key. It moves the cursor one field upward when items are being selected or changes the number/character forward when data or parameters of the ELI are being set.

N. Down key:

This is an LCD control key. It moves the cursor one field downward when items are being selected or changes the number/character backward when data or parameters of the ELI are being set.

O. Enter key:

This is an LCD control key. It returns to the previous page, and also confirms the number/character/item selected.

P. Inverter “On” Switch: This is an inverter control switch. When this switch is pushed simultaneously with the control key, the inverter will switch on.

Q. Inverter “Control” Switch:

This is an inverter control switch. When this switch is pushed in conjunction with the inverter “On” switch the inverter will activate. Similarly, when this switch is pushed with the inverter “Off” switch the inverter will shutdown. This switch acts as a safety switch to prevent accidental operation of the inverter.

R. Inverter “Off” Switch: This is an inverter control switch. When this switch is pushed simultaneously with the control switch the inverter will be turned off.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 24

7 Operation

After all the cables have been connected and power is present at the input terminal, the

ELI is ready to operate. Before initial start-up, re-check the following:

a. Make certain there is no foreign material left on, inside or around the ELI

b. Ensure all breakers and the battery disconnect switches are opened

c. Ensure all loads are switched off.

d. Check that the input frequency matches the ELI’s rated input frequency

e. Check that the input voltage matches the ELI’s rated input voltage

7.1 Switch On Procedure (Authorized Trained Personnel Only)

These start-up procedures can be performed with the AC utility source connected to or with only the batteries connected.

a.

Close the input breaker

– Energize the transformer.

b.

Close the reserve breaker

– The reserve and output LED on the status panel will light up, indicating the reserve static switch loop is energized and there is power on the output terminals. The power supplies within the ELI will energize and the internal fans will rotate.

c.

Close the rectifier breaker

- The rectifier will automatically start if the AC utility power connected is within operating parameters. The DC voltage will slowly rise (15 – 30 sec.) until the designated voltage is reached. The DC voltage is now ready for the inverter and battery bank.

d.

Close the battery breaker holder

- A breaker between the battery bank and the ELI is used for safety purposes. The batteries will start charging once the fuse door or breaker is closed. This fuse holder can be located within the ELI system or within the battery cabinets depending on rating.

e.

Push inverter on switch

– To turn on the inverter simultaneously press the inverter on switch (׀) and the control switch (◄►). The inverter will begin to function with inverter output within 4 sec. The load will automatically transfer to the inverter 3 sec. later. The ELI is now operating in normal mode.

f.

Check the status panel for correctness as shown in the diagram on the next page. All warning LED’s on the right hand side are off, two LED’s:

‘INVERTER ON’ and ‘INVERTER STATIC SWITCH’ on the left hand side should be lit, and the LED’s circle should also be lit. If the load is over 70%, the ‘70% LOAD’ LED will also be lit.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 25

BYPASS

RESERVE

RECTIFIER

BATTERY

INVERTER

RESERVE

STATIC SWITCH

INVERTER

STATIC SWITCH

OUTPUT

WARNING

RECT AC FAIL

RES AC FAIL

FUSE/TEMP

OVERLOAD

HIGH DC

BAT LOW

BAT LOW STOP

FAULT

INVERTER CONTROLS

INVERTER ON

INV STATIC

SWITCH ON

OUTPUT

SHORT CIRCUIT

FUSE/TEMP

INV SHUTDOWN

INVERTER FAIL

INV SHUTDOWN

BYPASS ON

INV SHUTDOWN

HIGH DC BUSS

INV SHUTDOWN

INV OVERLOAD

INV SHUTDOWN

70% LOAD

110% LOAD

125% LOAD

150% LOAD

STATUS

RESERVE

AC FAIL

RESERVE

FREQ FAIL

BATTERY LOW

BATTERY LOW

SHUTDOWN

RECTIFIER

AC FAIL

Ø

ROTATION

ERROR

RECTIFIER

SHUTDOWN

RECTIFIER

HIGH DC

BOOST

CHARGE

BATTERY

TEST

EMERGENCY

STOP

COMM.

ACTIVE

ON OFF

LCD CONTROLS

UP DOWN ENTER

Figure 7.1

Status Panel Display Under Normal Operation

Circles represent LED’s that are on.

To completely shutdown the ELI, please follow the following steps.

a.

Switch off the inverter

– The inverter can be switched off by simultaneously pressing the inverter off switch (O) and the inverter control switch (◄►).

The load will be automatically transferred to reserve without interruption.

b.

Open the battery breaker

– This will disconnect the batteries from the DC bus and the ELI no longer has back-up available. This is located within the

ELI system or within the battery cabinets.

c.

Open the rectifier breaker

– Opening the rectifier breaker will remove the power source from the DC bus. The DC bus will start to drop slowly until it reaches a save level of approximately 20VDC.

WARNING!

Completing the next step will turn off the power to the loads.

Make sure all loads have been turned off before proceeding or the external wraparound bypass has been initiated.

d.

Open the reserve breaker

– Before opening the reserve breaker you must make sure there is no critical load connected to the ELI that requires power.

NO OUTPUT POWER WILL BE SUPPLIED FROM THE ELI ONCE THE

RESERVE (UTILITY) BREAKER IS OPENED.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 26

e.

Open the input breaker

– transformers will de-energize.

f. Now that all power has been cut off within the ELI system. All LED’s, displays and fans should be off.

CAUTION!

Terminal strip and breakers may still be energized if the main input breaker feeding the ELI system is not turned off or open.

7.3 From Inverter To Manual Bypass Procedure

The following procedures will allow the service personnel to switch the ELI system to maintenance bypass mode without interrupting the output power to the loads.

a.

Switch off the inverter

– The inverter can be switched off by simultaneously pressing the inverter off switch (O) and the inverter control switch (◄►).

The load will be automatically transferred to reserve (utility) supply without interruption.

b.

Open the battery breaker

– This will disconnect the batteries from the DC bus and the ELI no longer has back-up available. This is located within the

ELI system or within the battery cabinets.

c.

Open the rectifier breaker

– Opening the rectifier breaker will take the power source away from the DC bus; therefore, the DC bus will start to drop slowly. After 5 min., the DC bus will drop to a safe level (approx.

20VDC).

d.

Close the bypass breaker

– The reserve breaker and reserve static switch are still conducting. When the maintenance bypass breaker is closed, power will flow through the bypass loop instead of the reserve loop because the impedance of the bypass loop is lower.

e.

Open the reserve breaker

– You can now open the reserve breaker to cut off any power within the ELI electronics.

NOTE

: To place the unit into Maintenance Bypass mode the fuse holders behind the control module (where all control PCB’s are stored) must be opened.

The system is now in Manual Bypass mode (or Maintenance Bypass mode).

CAUTION!

If the fuse holders have not been opened, power is still present and fans will be turning. If the fuse holders are open power is still present at the terminal strip and several terminals on the PCB’s.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 27

7.4 From Manual Bypass to Inverter Procedure

After the maintenance procedures and testing are complete you will need to restore the ELI back to its normal mode of operation without interrupting the power to the loads. The following procedures need to be followed.

a.

Close all fuse holders

– ensure all fuse holders behind the control module are closed. Fans will start spinning.

b.

Close the reserve breaker

– Wait 15 seconds for the reserve and output

LED on the status panel to light up, indicating the reserve static switch loop is energized and there is power on the output terminals. The power supplies within the ELI will also energized and the internal fans will rotate.

c.

Open the bypass breaker

– The inverter cannot be switched on when the maintenance bypass breaker is closed (because the CPU will sense the breaker and prevent the inverter from connecting directly to the AC source).

The reserve breaker is already closed so power goes through the reserve loop if the bypass breaker is open. AC power at the output will not be interrupted.

d.

Close the rectifier breaker

- The rectifier initiates automatically if the AC utility power connected is with in operating parameters. The DC voltage will slowly rise (15 – 30 sec.) until the designated voltage is reached. The DC voltage is now ready for the inverter and battery cabinets.

g.

Close the battery breaker

- A fuse holder is employed from the battery to the DC bus for safety purposes. The batteries will start charging once the breaker is closed. The breaker can be located within the battery cabinets.

h.

Push inverter on switch

– To turn on the inverter simultaneously press the inverter on switch (׀) and the control switch (◄►). The inverter will start working and the inverter output will be established in 4 sec. The load will automatically transfer to the inverter 3 sec. later. The ELI is now operating in normal mode.

e.

Check the status panel is correct, as shown in the diagram on the previous page. All warning LED’s on the right hand side are off, two LED’s:

‘INVERTER ON’ and ‘INVERTER STATIC SWITCH’ on the left hand side should be lit, and the LED’s circle should also be lit. If the load is over 70%, the ‘70% LOAD’ LED will also be lit.

To initiate a manual battery test turn off the input breaker to disconnect all ungrounded conductors. This process will simulate a failure of utility supply.

To be performed by service personnel. Consult service manual for more information.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 28

8 The LCD Display

The LCD displays Real Time information as to the status and operation characteristics of the UPS system and battery banks. In order to make the display sharp and readable, the

LCD is back-lit by LED’s. To prolong the life of the LED, the CPU will cut off the power of the LED 3 minutes after the last key has been pressed. The backlight will illuminate whenever a key has been pressed. This screen will pop up once the system power is enabled (i.e. the default screen).

8.1 Menu 0 – Main Menu

M O D E L : X X X X I I I S / N : 3 4 5 6 7 8 9 0 I D : 0 1

5 0 K V A I : 1 2 0 2 0 8 V 6 0 H Z O : 1 2 0 2 0 8 V 6 0 H Z

2 0 0 7 0 1 0 1 T U E 0 8 : 0 0 A M

Figure 8.1

Main Menu Display

The first row will display the greeting content set by the factory. The model no.

(MODEL), serial no. (S/N), and the identification no. (ID) are displayed in the second row. The third row will display the kVA rating, input rating and output rating of the UPS.

The serial no. is set by the factory for the convenience of maintenance personnel who may need to refer to the serial number for the correct spare parts and testing procedures. The identification no. is set only when multiple UPS systems are connected in parallel. Each UPS must have a unique number to identify itself, and will be set by a factory trained technician after installation. The YEAR/MONTH/DATE, DAY OF THE

WEEK, HOUR, MINUTE and AM/PM from the real time clock inside the UPS are displayed in the fourth row for user’s reference and for stamping the date and time in the historical data when an abnormal conditions occurs. By pressing one of the UP(

↑),

DOWN(

↓) or ENTER(↵) keys, the LCD will change to another screen.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 29

8.2 Menu 1 – Select Menu

S E L E C T M E N U

S T A T U S W A R N I N G F A U L T P A R A M E T E R S E T

R E A L T I M E D A T A

H I S T O R I C A L D A T A E X I T

Figure 8.2

Select Menu Display

MENU 1 is reached by pressing any button on the opening screen and is also the default menu. From this menu the personnel can select STATUS WARNING FAULT, REAL TIME

DATA, HISTORICAL DATA and PARAMETER SET menus. To select an option move the cursor (

→) by pressing the UP (↑) key, or the DOWN (↓) key. Selections are confirmed by pressing the ENTER (

↵) key. The user will be sent to the menu the cursor is pointing to. If the item ‘PARAMETER SET’ is selected, the LCD will jump into a screen that will prompt the user for a password. Contact service provider for more information.

8.3 Menu 2 – Status Warning Menu

S T A T U S

R E C T I F I E R = O N

W A R N I N G

I N V E R T E R = O N

L O A D O N I N V E R T E R

Figure 8.3

Status Warning Menu Display

The Status/Warning menu is accessed through MENU 1 by selecting STATUS

WARNING FAULT. The left-hand side of this menu shows the real time status of the rectifier, inverter and static switch, while the right hand side shows the warning or fault condition if any. Under normal condition, the LCD display should be exactly the same as the figure shown above. When abnormal conditions occur it will be shown under the title

< WARNING >, but this will be overridden by a “fault” message if more serious abnormal conditions occur and the title < WARNING > will then change to < FAULT >.

For example, if a short circuit has occurred, this screen will display as follows:

S T A T U S

R E C T I F I E R = O N

I N V E R T E R = O F F

L O A D O N I N V E R T E R

F A U L T

S H O R T C I R C U I T

Figure 8.4

Warning Status Display with Fault Condition

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 30

The inverter will automatically shut off under a short circuit fault. The CPU is designed to detect short circuits and in order to avoid unnecessary tripping of the reserve (utility supply) breaker, the static switch will remain open or inactive. (There will be no output power present)

Listed below are all the warning conditions that can be displayed (they are arranged in order of priority, starting with the highest priority):

1 st

row: BYPASS ON – Output is being supplied by the reserve

RECT AC FAIL

– AC utility source failure

RECTIFIER PHASE ERROR

– AC utility phase loss or one phase out of operating parameters

RESERVE FREQ. ERROR

– AC utility frequency is out of parameters and reserve has been disabled until error is corrected

2 nd

row: 170% OVERLOAD – over 170% maximum capacity for the ELI system.

3 rd

row: BATTERY LOW STOP – Battery have been exhausted.

BATTERY LOW

– Batteries have passed the low voltage level and will soon be exhausted.

BATTERY GND FAULT

– Battery cabinet not grounded properly.

BATTERY

– performing test on the batteries.

Listed below are all the fault conditions that can be displayed:

1 st

row: HIGH DC SHUTDOWN – DC Bus voltage out of operating range.

2 nd

row: SHORT CIRCUIT! – a short circuit condition has occurred on the output. overheating.

OVERLOAD SHUTDOWN

– system has exceeded the overload limit beyond the operating window.

EMERGENCY STOP –

user has activated the emergency stop feature. parameters.

3 rd

row: BYPASS ON SHUTDOWN – inverter failure, system operating in bypass mode.

The UP (

↑) or DOWN (↓) key has no function in this menu. The screen will go back to

MENU 1, when ENTER (

↵) is pressed.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 31

8.4 Menu 3 – Real Time Data Menu

R E A L

R E C T I F I E R D A T A

T I M E D A T A

O T H E R D A T A

R E S E R V E D A T A

O U T P U T D A T A E X I T

Figure 8.5

Real Time Data Menu Display

MENU 3 is reached by selecting REAL TIME DATA on MENU 1. The cursor(→) is used to select what type of real time data the user would like to view, RECTIFIER DATA, RESERVE

DATA, OUTPUT DATA and OTHER DATA. To select one of the different menu options move the cursor(

→) until it is pointing at the correct selection, by press the UP (↑) key or the

DOWN (

↓) key. To confirm and select the menu option press the ENTER (↵) key.

Selecting the ‘EXIT’ option (blinking instead of pointed by cursor) will return you to

MENU 1.

Rectifier Data Menu

R E C T I F I E R D A T A >

R E C T I F I E R F R E Q U E N C Y = X X H Z

R - N = X X X V a c S - N = X X X V a c T - N = X X X V a c

Figure 8.6

Rectifier Data Menu Display

This menu is reached by selecting RECTIFIER DATA on MENU 3. The information provided on this menu is the real time readings of the rectifier input; RECTIFIER

FREQUENCY, R-N/S-N/T-N VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R

VOLTAGE on delta (

≥) configured systems.

The UP (

↑) or DOWN (↓) key has no function in this menu. The screen will return to

MENU 3 when the ENTER (

↵) key is pressed.

Reserve Data Menu

< R E S E R V E D A T A >

R E S E R V E F R E Q U E N C Y = X X H Z

R - N = X X X V a c S - N = X X X V a c T - N = X X X V a c

Figure 8.7

Reserve Data Menu Display

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 32

This menu is reached by selecting RESERVE DATA on MENU 3. The information provided on this menu is the real time readings of the reserve input; RESERVE

FREQUENCY, R-N/S-N/T-N VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R

VOLTAGE on delta (

≥) configured systems.

The UP (

↑) or DOWN (↓) key has no function in this menu. The screen will return to

MENU 3 when the ENTER (

↵) key is pressed.

Output Data Menu

O U T P U T D A T A

O U T P U T F R E Q U E N C Y = X X H Z

L O A D : R = X X X % S = X X X % T = X X X %

R - N = X X X V a c S - N = X X X V a c T - N = X X X V a c

Figure 8.8

Output Data Menu Display

This menu is reached by selecting OUTPUT DATA on MENU 3. The information provided on this menu is the real time readings of the inverter or reserve output (depending on what mode the system is in); OUTPUT FREQUENCY, LOAD % OF R/S/T, OUTPUT R-N/S-N/T-N

VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R VOLTAGE on delta (

Δ) configured systems.

The UP (

↑) or DOWN (↓) key has no function in this menu. The screen will return to

MENU 3 when the ENTER (

↵) key is pressed.

Other Data Menu

O T H E R D A T A

T E M P E R A T U R E = X X C

D C V O L T A G E = X X X V d c

C H A R G E C U R R E N T = X X X A

Figure 8.9

Other Data Menu Display

This menu is reached by selecting OTHER DATA on MENU 3. The information provided on this menu is the real time readings of the ELI system; TEMPERATURE, DC

VOLTAGE, CHARGE OR DISCHARGE CURRENT.

When the ELI system is operating in normal mode the last line will read CHARGE

CURRENT and will represent the amount of current being supplied to the batteries.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 33

When the system changes to back-up mode the last line will change to DISCHARGE

CURRENT displaying how much current is being supplied to the inverter from the batteries (figure below).

O T H E R D A T A

T E M P E R A T U R E = X X C

D C V O L T A G E = X X X V d c

D I S C H A R G E C U R R E N T = X X X A

Figure 8.10

Other Data Menu Display when system in Back-up

The UP (

↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU

3 when the ENTER (

↵) key is pressed.

8.5 Menu 4 – Historical Event Menu

D A T E T I M E E V E N T S >

2 0 0 2 \ 0 3 \ 2 9 0 9 : 3 2

2 0 0 2 \ 1 1 \ 0 1

2 0 0 3 \ 0 3 \ 1 0

2 2 : 1 5

1 5 : 4 7

R U N : 2 1 Y R 0 3 M O

Figure 8.11

Historical Event Menu Display

MENU 4 is reached by selecting HISTORICAL DATA on MENU 1. All abnormal events are stored on the EEPROM and viewed through this menu based on the time each event occurred. The record display starts with the date and time stamp allowing the user or maintenance personnel to trace back that occurrence. A maximum of 77 records can increased to 154 records with the addition of a second EEPROM. These records are hard coded onto the EEPROM and will not be erased by cutting off the power supply or during a complete shutdown of the ELI, i.e. they will be kept in the EEPROM forever until they’re overwritten by the 78 th

(or the 155 th

) events.

The three most recent records are displayed at one time on the view screen. The displayed records will move one record upward when the UP (

↑) key is pressed, and move one record downward when the DOWN (

↓) key is pressed.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 34

Below is a list of the abnormal conditions that are stored and can be displayed:

HIGH DC SHUTDOWN / SHORT CIRCUIT! / FUSE/OVERHEAT / OVERLOAD

SHUTDOWN / EMERGENCY STOP / INVERTER ABNORMAL / BYPASS ON

SHUTDOWN

The display in the top right corner of the screen is the ELI installation time displayed in year/month. This information is provided to allow the user or the maintenance personnel to have a reference point to schedule the next preventative maintenance visit.

To return to MENU 1 press the ENTER (

↵) key.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 35

9 INTERFACE CONNECTIONS

All user interfaces are connected to or from PCB 3R, see the figure below.

Figure 9.1

3R PCB Layout

Eight, normally open, dry contact terminals are provided. Maximum rating is

16A/250VAC or 16A/30VDC.

Definitions:

INVON – Short whenever inverter is on, open when inverter is off.

OVL – Short whenever ELI is overloaded.

FAULT – Short when ELI encounters a fault condition such as high DC shutdown, short circuit, fuse/overheat, overload shutdown, emergency stop, inverter abnormal, and bypass on shutdown. The contact is latched until it is manually reset (off switch) or the fault has been cleared for 30 seconds.

SS – Short when the inverter is supplying output power, open when reserve is supplying output power (The two output will never conduct simultaneously).

BYPASS – Short when the maintenance bypass breaker is closed, open when the breaker is opened.

BACK-UP – Short when the ELI system is in back-up mode (batteries supplying DC Bus).

BATL – Short when low battery condition occurs and the batteries are about to be exhausted.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 36

COM – This contact is the OR result of the signals described above. That is, if any other contact closes, this contact will close too. The signal to be read is selectable through SWR2. See the figure below.

Figure 9.2

Dry Contact Layout

9.2 Software for PC Monitoring

The monitoring software allows for a server or workstation to monitor the ELI operation. When the software is installed on a PC it can monitor 1-99 ELI’s connected in series via a DB9 connection. The connector on the ELI side is RS-485

(for long distance transmission) therefore a RS-485 Ù RS-232 adapter (hardware) is required to modify the signal (not included with ELI system).

9.3 Emergency Power off Connection

One pair of terminals (CNR 3) are provided to allow the user to shutdown the ELI system in an emergency situation (e.g. fire, short circuit, etc.). A minimum of

10mA is needed for activate the photo-coupler.

One RS-485 and one RS-232 are provided to communicate with more sophisticated optional communication modules. Each connector is dedicated to one type of external module.

9.5 Web Monitoring Module (SNMP Module)

Simple Network Management Protocol. The SNMP Card is an Interface to the

Ethernet network, and provides ELI information via the standard SNMP protocol.

The ELI can therefore be managed via an internet browser. This information can be used to determine the state of the ELI and guarantee safe and orderly shutdown of servers and workstations when needed.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 37

9.6 Emergency Lighting Notification

Figure 9.3

Fire Alarm Panel Terminals

* Preset at factory.

The fire alarm panel terminals fare provided to allow the fire alarm panel recognition of the following fault conditions using normally open contacts:

1) Output overload condition

2) Inverter failure due to: a. Rectifier DC output to high b. Output short circuit c. Inverter fuse open or over temperature condition d. Inverter overload condition e. Emergency stop activation f. Inverter output outside or parameters g. Bypass activated, inverter shutdown

3) Manual bypass activation

4) Utility AC failure (on battery)

5) Battery low condition

6) No Output Voltage Present

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 38

10 Battery Backup Units (BBU)

The battery cabinets have been designed with the same style and appearance as the

ELI cabinet for ease of installation and cosmetic value. Reinforcement has been added to strengthen the cabinet for the additional weight and transportation. The Battery

Banks contain the batteries and provide the runtime for the ELI system.

Physicals for 3 Ø Battery Cabinet

3 Ø

: Width – 1321mm, Depth – 864mm and Height – 1930mm

Figure 10.1

3 Phase Battery Cabinet Layout

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 39

Battery cabinets feature slide-out shelves. Prior to installation of the BBU, the side panels should have been removed and the screws holding the battery slide-out shelves in place should have been unscrewed, allowing for ease of battery replacement.

CAUTION! Only qualified service personnel should attempt battery bank maintenance. Removal of the side access panels exposes personnel to potential dangerous voltages and shock hazards that may cause damage, injury or death.

If screws have not been properly removed prior to BBU installation, completely shut down

ELI, wait for 30 minutes until capacitors have fully discharged and disconnect ELI from BBU prior to servicing.

Figure 10.2

Slide-out BBU shelves

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 40

10.1 Run Time Charts

THREE PHASE 30 MINUTES BACKUP CONFIGURATIONS

Standard Battery Systems for 30 minute runtime

Type R Battery Maintenance-Free Sealed Lead-Acid - 10 Year Design Life Expectancy

System

Capacity Rating

8kW 12kW 16kW

ELI Dimensions

WxDxH (in)

22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63”

ELI Dimensions

WxDxH (mm)

BBU

Dimensions

WxDxH (in)

BBU

Dimensions

WxDxH (mm)

System

Configuration

Estimated

System Weight

– lb/kg

550 x 812 x

1,600

1,315 x 850 x

1,945

A

2,627 / 1,194

550 x 812 x

1,600

1,315 x 850 x

1,945

A

3,113 / 1,415

550 x 812 x

1,600

1,315 x 850 x

1,945

A

3,639 / 1,654

550 x 812 x

1,600

1,315 x 850 x

1,945

A

4,352 / 1,978

550 x 812 x

1,600

52” x 34” x 76” 52” x 34” x 76” 52” x 34” x 76” 52” x 34” x 76” 52” x 34” x 76”

1,315 x 850 x

1,945

A

5,311 / 2,414

THREE PHASE 60 MINUTES BACKUP CONFIGURATIONS

550 x 812 x

1,600

2 * (52” x 34” x

76”)

2 * (1,315 x

850 x 1,945)

B

7,713 / 3,506

550 x 812 x

1,600

2 * (52” x 34” x

76”)

2 * (1,315 x

850 x 1,945)

B

8,021 / 3,646

Standard Battery Systems for 60 minute runtime

Type R Battery Maintenance-Free Sealed Lead-Acid - 10 Year Design Life Expectancy

System

Capacity Rating

8kW 12kW 16kW 24kW 32kW

ELI Dimensions

WxDxH (in)

ELI Dimensions

WxDxH (mm)

BBU

Dimensions

WxDxH (in)

BBU

Dimensions

WxDxH (mm)

System

Configuration

Estimated

System Weight

– lb/kg

22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63”

550 x 812x

1,600

52” x 34” x 76” 52” x 34” x 76” 52” x 34” x 76” 52” x 34” x 76”

1,315 x 850 x

1,945

A

3,036 / 1,380

550 x 812x

1,600

1,315 x 850 x

1,945

A

3,562 / 1,619

550 x 812x

1,600

1,315 x 850 x

1,945

A

4,066 / 1,848

550 x 812x

1,600

1,315 x 850 x

1,945

A

5,157 / 2,344

550 x 812x

1,600

2 * (52” x 34” x

76”)

2 * (1,315 x

850 x 1,945)

B

7,581 / 3,446

40kW

550 x 812x

1,600

2 * (52” x 34” x

76”)

2 * (1,315 x

850 x 1,945)

B

9,324 / 4,238

48kW

550 x 812x

1,600

2 * (52” x 34” x

76”)

2 * (1,315 x

850 x 1,945)

B

9,632 / 4,378

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 41

THREE PHASE 90 MINUTES BACKUP CONFIGURATIONS

Standard Battery Systems for 90 minute runtime

Type R

Battery

System

Capacity

Rating

ELI

Dimensions

WxDxH (in)

ELI

Dimensions

WxDxH (mm)

Maintenance-Free Sealed Lead-Acid - 10 Year Design Life Expectancy

8kW 12kW 16kW

22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63” 22” x 32” x 63”

550 x 812 x

1,600

550 x 812 x

1,600

550 x 812 x

1,600

550 x 812 x

1,600

550 x 812 x

1,600

550 x 812 x

1,600

550 x 812 x

1,600

BBU

Dimensions

WxDxH (in)

BBU

Dimensions

WxDxH (mm)

System

Configuration

52” x 34” x 76” 52” x 34” x 76” 52” x 34” x 76”

1,315 x 850 x

1,930

A

1,315 x 850 x

1,930

A

1,315 x 850 x

1,930

A

2 * (52” x 34” x 76”)

2 * (1,315 x

850 x 1,930)

B

2 * (52” x 34” x 76”)

2 * (1,315 x

850x 1,930)

B

3 * (52” x 34” x 76”)

3 * (1,315 x

850 x 1,930)

C

3 * (52” x 34” x 76”)

3 * (1,315 x

850 x 1,930)

C

Estimated

System

Weight – lb/kg

3,485 / 1,584 4,794 / 2,179 4,871 / 2,214 9,038 / 4,108 9,192 / 4,178 13,204 / 6,002 13,512 / 6,142

*

**

Input, output voltages are 3 phase 4 wire plus ground (wye) configuration.

Consult factory for other voltage configurations.

*** Longer runtimes available. Consult factory.

**** Other voltage configurations available. Consult factory.

***** Other amp ratings available. Consult factory.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 42

10.2 BBU Configurations

52"

34"

22"

32"

35"

25"

DRIP SHIELD for ELI

25"X35"X8"

650 x 900 x 203

34

"

BATTERY CABINET

52"X34"X76"

1315 x 850 x 1945

ELI CABINET

22"X32"X63"

550 x 812 x 1600

Figure 10.3

Configuration A

52" 52"

22"

32"

BATTERY CABINET

52"X34"X76"

1315 x 850 x 1945

BATTERY CABINET

52"X34"X76"

1315 x 850 x 1945

ELI CABINET

22"X32"X63"

550 x 812 x 1600

Figure 10.4

Configuration B

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12

35"

25"

DRIP SHIELD for ELI

25"X35"X8"

650 x 900 x 203

43

34"

52" 52" 52" 22"

32"

35"

25"

DRIP SHIELD for ELI

25"X35"X8"

650 x 900 x 203

BATTERY CABINET

52"X34"X76"

1315 x 850 x 1945

BATTERY CABINET

52"X34"X76"

1315 x 850 x 1945

BATTERY CABINET

52"X34"X76"

1315 x 850 x 1945

ELI CABINET

22"X32"X63"

550 x 812 x 1600

Figure 10.5

Configuration C

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 44

11 Options

This section provides a brief introduction to some of the options available for our ELI system.

Warning!

Similar products from other manufacturers will not fit into our ELI systems.

The installation of any option requires professional settings and should only be performed by the factory or factory trained representatives.

11.1 Emergency Stop Switch

This switch is used to immediately remove power from the load in the event of an emergency condition e.g. electrical shock, burning of the load or water located around the ELI. When the emergency stop button is pushed, the inverter will stop running immediately and the static switch does not activate. There will be no AC supply at the output.

This shutdown condition is latched until a manual reset has been performed.

Manual reset is performed by pressing the inverter off switch (O) and the inverter control switch (WX) simultaneously. Once the system is reset follow the Start-up procedure discussed earlier to turn the system back on.

11.2 Remote Display Panel

The remote panel is a display module with LCD and LED’s that can monitor 1 –

99 ELI’s via a DB9 connected in series from distance < 1000m. It allows for remote monitoring of the ELI status and alarms.

11.3 12 Pulse Rectifier

Located inside the ELI system cabinet. The 12-pulse rectifier is an optional feature for 8KW to 48KW systems. The 12-pulse rectifier is designed to reduce the input harmonic distortion to less than 2%.

11.4 External Wrap Around Bypass

A separate cabinet that allows for complete removal of the ELI system from the load, while still supplying the load with conditioned power. Systems can include isolation transformer for different voltage configurations, distribution panels and

Kirk-Key interlock protection to ensure proper operation.

11.5 Normally Off Function

All Normally Off loads shall not exceed 50% of the ELI rating per phase.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 45

12 Technical Specifications

8KW to 48KW ELI 3Ø Input - 3Ø Output

8 12 16 24 32 40 48

RECTIFIER

Input Voltage 208V/480V/600V 3 phase 3 and 4 wire + G

Input Range

Input Frequency

180-750V

50 / 60 Hz +/- 7%

Input Power Factor

Normal Input

Current(A) (Based on

208VAC)

Maximum Input

Current(A) (Based on

208VAC)

< 1

36 54 71 107 142 178 213

Current THD 6 PULSE : 30% ; 12 PULSE :9%

Power Walk In (adjustable) 0% - 100% : 20 sec

Efficiency 96%

Voltage Regulation

Ripple Voltage

BATTERY

Battery Type

No. Of Cells

1%

0.5%

Maintenance free Sealed Lead Acid

174

Voltage Range

Maximum Charge

Current (ADC)

Battery Low

Voltage

Battery Low Stop

Voltage

Boost Charge

Float Charge

295 – 410VDC

3 4 5 8 10 13 15

320VDC

295VDC

410VDC

392VDC

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 46

8 12 16 24 32 40 48

INVERTER

DC Input Range

Wave Form

Output Voltage (Adjustable)

Crest Factor

Output Power Factor

Voltage Regulation 100%

Unbalance Load

Frequency Lock Range

Output Frequency (Free

Running)

295 – 410VDC

Sinusoidal

120/208V 277/480V 347/600V 3 Phase

4 Wire + G

3 : 1

0.8

+ / - 1 %

45 – 55 Hz / 55 – 65 Hz

50 / 60 Hz + / - 0.1 Hz

Output

Voltage

Tolerance

Load step 0% - 100%

- 0%

Load step 0% - 50% -

0%

100% unbalanced load (Ph-N)

Phase Shift Under 100%

Unbalance Load

THD (Linear Load)

- <110%

- 110 – 125%

Overload

- 125 – 150%

- > 150%

Efficiency (100% Load)

+/- 3%, recovering in 1 cycle

+/- 2%, recovering in 1 cycle

+/- 3%

120° + / -5%

< 2 %

CONTINUOUS

15 min

5 min

30 sec

94% 94% 94% 94% 94% 94% 94%

STATIC SWITCH

Voltage Range

Frequency Range

+- 20% of input voltage (Line to Neutral)

45 – 55 Hz / 55 – 65 Hz

Efficiency 99.5%

Transfer

Time

- Mains -> Inverter

- Inverter -> Mains

0 ms

0 ms

Overload

- 200%

- 400%

Isolation With Output

30 sec

1 sec

YES

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 47

8 12 16 24 32 40 48

OVERALL CHARACTERISTICS

90% 90% 90% 90% 90% 90% 90%

Operating Environment:

- Temperature

- Humidity

- Altitude

0 – 40°C (32 – 104°F)

0% - 95% (non–condensing)

<1500 m above sea level

Maximum Heat Dissipation(kW) 0.89 1.3 1.8 2.7 3.6 4.4 5.3

Dimension:

- HEIGHT(mm)

- WIDTH(mm)

- DEPTH(mm)

- Audible Noise

Standards:

- CSA

- CE

- EN50091-1,-2

- FCC Part 15 Class A

Protections:

- Short Circuit

- Lightning

- EMC Filter

- Galvanic Isolation

Data Display By LCD

1600

559

815

< 65 dBA (AT 1 m)

Yes

Yes

Yes

Yes

Rectifier, Reserve, Bypass NFB

MOV

Input & Output

Between Input & Output

Yes

Indications & Alarms:

- LED, LCD, Buzzer

Dry Contact

Yes

Yes

Battery Start Yes

All specifications mentioned above are subject to change without prior notice.

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 48

Specification Table for Three Phase Inverters

Model Size 8kW 12kW 16kW 24kW

Output Power

Factor

Input // Output

Voltage

Combinations

Available 3 phase

AC Input

Voltage- Input

Service Amps

Output Voltage and Maximum

Output Current in Amperes at 100% Load

Standard

Charger Size

(amps)

DC System

Voltage

0.8

208/120V – 40A

480/277V – 20A

600/347V – 15A

208/120V – 70A

480/277V – 30A

600/347V – 30A

208/120V – 90A

480/277V – 40A

600/347V – 30A

208/120 // 208/120

480/277 // 208/120

600/347 // 208/120

208/120 // 480/277

480/277 // 480/277

600/347 // 480/277

208/120 // 600/347

480/277 // 600/347

600/347 // 600/347

208/120V –

125A

480/277V – 60A

600/347V – 50A

208/120V –

175A

480/277V – 80A

600/347V – 60A

208/120V –

200A

480/277V – 90A

600/347V – 70A

208/120V –

250A

480/277V –

125A

600/347V – 90A

208/120V – 22A

480/277V – 10A

600/347V –8A

208/120V – 33A

480/277V – 14A

600/347V –12A

208/120V – 44A

480/277V – 19A

600/347V – 15A

208/120V – 67A

480/277V – 29A

600/347V – 23A

208/120V – 89A

480/277V – 39A

600/347V – 31A

208/120V – 111A

480/277V – 48A

600/347V – 38A

208/120V – 133A

480/277V – 58A

600/347V – 46A

3 4 5 8

348VDC nominal

32kW

10

40kW

13

48kW

15

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 49

13 Contact Information

QA / Warranty Questions

Always On UPS Systems Canada Inc.

Bldg 1 – 150 Campion Road,

Kelowna, BC, Canada, V1X 7S8

Phone: (250) 491-9777 Ext 209

491-9775

Email: [email protected]

Website: www.alwayson.com

Software Questions

Always On UPS Systems Canada Inc.

Bldg 1 – 150 Campion Road,

Kelowna, BC, Canada, V1X 7S8

Phone: (250) 491-9777 Ext 204

Email: [email protected]

Website: www.alwayson.com

Additional Purchases or Upgrades

Always On UPS Systems Canada Inc.

Bldg 1 – 150 Campion Road,

Kelowna, BC, Canada, V1X 7S8

Phone: (250) 491-9777 Ext 451

491-9775

Email: [email protected]

Website: www.alwayson.com

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 50

M4102_Borealis_8-48Kw_Operators_Manual V4.0 2013-06-12 51

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement