POWER WAVE 4 - OnLine Power, Inc.
Contents
1. will automatically restart 30 seconds after abnormal situation has been cleared HIGH DC DC voltage over 430VDC and the bus voltage will be limited at this voltage BOOST CHARGE the batteries are being boost charged by the rectifier BATTERY TEST batteries are being tested EMERGENCY STOP inverter shutdown due to emergency stop switch pushed DATA LINE blinks when data is transmitted to or received from the communication port Page 16 of 26 6005 184 Rev C Warning LEDs When abnormal condition happens these LEDs will light to warn the user according to the cause of the faulty condition Therefore all these LEDs should be extinguished under normal condition These LEDs are as shown below RECT AC FAIL rectifier AC input is abnormal either due to AC magnitude out of the range or phase rotation error rectifier shutdown RESERVE FAIL reserve AC input is abnormal either due to AC magnitude out of range or frequency out of range FUSE TEMP Inverter fuse is blown or over temperature condition exists OVERLOAD output is overloaded by over 110 125 or 150 HIGH DC the LED will light as long as the DC voltage is over 430VDC BAT LOW the LED will light as long as the DC voltage is lower than 320VDC BAT LOW STOP the LED will light as long as the DC voltage is lower than 295VDC inverter cannot start FAULT the inverter is shutdown due to abnormal conditions such as overload short circuit high2. 000000000000 6005 184 Rev Front Panel A GM Com CM Cu dX e P TRUE GALVANIC ISOLATED UPS F G H I J K ID M The front panel is located at the front of the PCB holder It gathers the real time information of the UPS and shows them clearly to the user It also provides switches for controlling and setting the UPS Through this panel the UPS can be not only a stand alone machine supplying the load but also closely monitored by the user Each part of the panel is explained below A LCD display Real time status data or historical events are displayed on the LCD The UPS parameters real time clock inverter and buzzer also can be set through this LCD The LCD is back lighted by LEDs to provide a sharp display In order to lengthen the LED s life time the LED are automatically shut off 3 minutes after no key is activated but will light up again when one of the up down enter key is pushed B Status LEDs 24 LEDs representing all of the important information of the UPS provide the most up to date information to the user Therefore these LEDs are especially important when abnormal conditions occur The 24 information items are as shown below INVERTER ON inverter is running INVERTER SS inverter static switch conducts while the reserve static Switch is opened SHORT CIRCUIT UPS output is in short circ
3. The test results shall be documented signed and dated for future reference NOTE This Guide Specification follows the Construction Specification Institute guidelines per CSI MP 2 1 MP 2 2 It is subject to change due to product improvement and or enhancement Please use this document as a guide specification and do not hesitate to contact our application engineering department should you have any further questions or special requirements You can contact us at 800 227 8899 or via e mail sales onlinepower com tech onlinepower com 2 15 WARRANTY Inverter Module The Inverter manufacturer shall warrant the Inverter against defects in materials and workmanship for a period of twenty four 24 months The warranty shall cover all parts and labor for one 1 year period beginning from the start up or 18 months from the ship date whichever comes first Optional 1 year extended warranty and maintenance contract packages shall also be available at the end of the factory maintenance period 2 16 Wiring Installation Inverter cabinet conduit entry arrangement shall allow for flexibility of user wiring installation The wiring shall be routed thru the top or either side of the cabinet 2 17 Wiring Termination The Inverter input and output power connections shall be hard wired within the cabinet Optional input line cable and output distribution panel shall be available limited range of units only please consult factory for details Inpu
4. Voltage 348VDC Range 295 410VDC Low Battery Warning Voltage 320VDC Low Battery Shut down Voltage 295VDC Boost Charge Voltage 402VDC Float Charge Voltage 390VDC Standard Run Time 90 minutes for UL924 For battery cabinet dimensions including other run time refer to battery Table 2 and Tabel 2A 2 4 3 Inverter and Output Specification DC input Voltage Range to Inverter 285 420VDC inverter can be started without an AC source Output Waveform Sinusoidal Wave Output Power factor 0 8 PF Output Voltage Regulation at 100 Unbalanced Load 1 Output Frequency Tolerance 0 1 Hz Phase Shift Under 100 Unbalanced Load 120 0 5 Output Voltage Total Harmonics THD Less than 296 6005 184 Rev A Page 3 of 26 2 4 4 2 4 5 6005 184 Rev A Output Maximum Peak Current 125 of Rated Output current Over Load o Less than 110 Load Continuous o 125 150 5 minutes o Higher than 150 30 Seconds Static Switch Specification Voltage Range o 96 144VAC Line to Neutral for 208 120V units o 222 332VAC Line to Neutral for 480 277V units Efficiency 99 596 Transfer Time o From Main Input source to Inverter 0 2ms o From Inverter to Main Input source 0 2ms Over Load o 100 for 30 Seconds o 300 for 7 Seconds Isolation with Output System Overall Specification Operation Mode Double conversion mode Green Mode Hybrid design customer selectable for green mode
5. 184 Rev A Page 22 of 26 2 8 4 Reserve Mode BYPASS 227 RESERVE zs w lt 2 RECTIFIER c fa Y g o 5 B RECTIFIER INVERTER ISOLATION Iac TRANSFORMER zh When the inverter is in an abnormal condition such as over temperature short circuit abnormal output voltage or overloaded for a period exceeding the inverter s limit the inverter will automatically shut down in order to protect itself from damage If the utility power is normal the static switch shall transfer the load to the reserve source without interruption of AC output 2 8 5 Maintenance Bypass Mode BYPASS 1 RESERVE E o z RECTIFIER 9 o o RECTIFIER INVERTER ISOLATION TRANSFORMER 41 In case of UPS maintenance or battery replacement and where the load cannot be interrupted the user can turn off the inverter close the bypass breaker and then open the rectifier and reserve breakers The AC output will not be interrupted during manual bypass transfer procedure Therefore the maintenance bypass switch keeps continuously supplying power to the load Electricity will not exist in UPS except the output transformer thus ensuring the safety of service personnel Generally the UPS is expected to run 24 Hours a day in normal operation mode once it is installed except when the utility power fails under overload conditions or during maintenance
6. browser UPSCOM is a hardware software combination installed on a PC to monitor multiple UPSs with DB9 connection in series The connector on the UPS s side is RS 485 for long distance transmission therefore an RS 485 RS 232 adapter hardware is required to modify the signal The software and hardware together form a package called UPSCOM See the UPSCOM specification for further information Auto Dialing Module UPSCALL In case abnormal situations occur UPSCALL will automatically dial specified phone numbers to inform management to take prompt action The module with built in 23A12V battery consumes power only when in the process of dialing so as to be operated under AC source failure Furthermore with functions of multiple phone number setting and dialing UPSCALL has no need of dedicated lines and can offer user a prompt and convenient way for monitoring the UPS See the UPSCALL M specification for further information Battery Monitoring Battery Monitoring system is available consult factory for this option Output Auxiliary CBs External output Panel Boards with 3 phase main Circuit breaker is available in external enclosure to the UPS 1 pole 20 amp circuit Circuit Breakers up to 20 Normally OFF output Auxiliary CBs 1 pole 20 amp circuit Circuit Breakers up to 20 Higher kAIC Circuit Breakers Page 24 of 26 2 9 11 Earthquake Protection The cabinet can be evaluated for earthquake compliancy con
7. fast transfer less than 2ms Overall System Efficiency Double conversion mode 91 93 Vary by kVA Overall System Efficiency Green Mode 96 98 Vary by kVA Overload 110 125 15 minutes 125 150 5 minutes Higher than 150 30 Seconds Operating Environment o Operating Temperature 0 40 C 32 F 104 F o Humidity 0 90 None Condensing o Altitude Less than 1500 meter 5000 feet Above Sea level Maximum Heat Dissipation o BTU HR Refer to the Table 3 o Weight Refer to the Table 3 o Dimensions Refer to the Table 3 Audible Noise Less than 65dBA at 1 meter 39 4 inches Protections Page 4 of 26 o Short Circuit for Rectifier By pass o MOV for Lightning o Filter for Input and Output Status Panel o It shall consist of 4 X 40 character LCD display for real time status Data or Historical Events 24 Status LEDs 8 Warning LEDs Mimic Display Audible Alarm Inverter ON OFF Switch LCD control Switch Ooo0o00 2 5 Features and Advantages 6005 184 Rev A Reliable input protection The UPS shall utilize Circuit breakers in each individual input loop to ensure power can continue through another loop in case of breaker trip caused by an abnormal condition in either rectifier or load Input surge protection The UPS shall employ MOV surge protector on the input providing protection to both UPS and the load from any lightning surges or surges caused by neighboring large loads EMI suppr
8. is determined according to the reserve input voltage and frequency to protect supplying incorrect power to the load Finally there is a double check by the CPU as to whether the transfer is successful or not 2 6 4 Maintenance Bypass 6005 184 Rev A Page 13 of 26 6005 184 Rev The Maintenance Bypass Switch shall use 3 circuit breaker scheme Rectifier Reserve By pass The maintenance bypass switch is already installed inside the UPS for convenience and It should be open under normal operation and only closed during maintenance All power supplies inside the UPS should be disconnected before touching any parts inside the UPS Thus the maintenance bypass switch is a necessity to maintain AC power at the output and yet keep maintenance personnel safe at the same time If the bypass breaker is closed under normal operation the inverter will stop and the load will be automatically transferred to reserve to prevent the inverter connecting directly to the AC source Of course you cannot switch on the inverter as long as the maintenance bypass breaker is closed NOTE To properly use the maintenance bypass breaker switch off the inverter first The static switch will automatically transfer the load to reserve without dead time Then one can close the maintenance bypass breaker and then open the reserve breaker so that the load gets power from the output without interruption Page 14 of 26 2 7 System Diagnostics Alarm 2 7 1
9. shall be available through an extensive network to ensure around the clock parts availability throughout the country Customer Support Parts Coordinators shall be on call 24hrs day 7days week 365 days a year for immediate parts dispatch Parts shall be delivered to the site within 24 hours 2 12 Maintenance Training In addition to the basic operator training conducted as a part of the system start up classroom courses for customer employees shall be made available by the manufacturer The course shall cover Inverter theory location of subassemblies safety battery considerations and Inverter operational procedures It shall include AC DC and DC AC conversion techniques as well as control and metering Troubleshooting and fault isolation using alarm information and internal self diagnostics interpretation shall be stressed 2 13 Maintenance Contracts A comprehensive offering of preventive and full service maintenance contracts shall be available An extended warranty and preventive maintenance package shall be available All services shall be performed by factory trained Service Engineers 6005 184 Rev A Page 25 of 26 2 14 Site Testing The manufacturer s field service personnel shall provide site testing if requested The testing shall consist of a complete test of the Inverter system and the associated accessories supplied by the manufacturer A partial battery discharge test shall be provided as part of the standard start up procedure
10. 184 Rev A FILTER amp L i PROTECTION RECTIFIER INVERTER NETWORK w General Topology FILTER TO LOAD ISOLATION TRANSFORMER T BATTERY The UPS system is composed of input breakers input filter amp protection network rectifier battery bank inverter static switch bypass breaker isolation transformer and output filter The basic topology is shown in the diagram above Under normal AC mode energy from the AC source is converted to DC power and supplied to the inverter to charge the batteries to its full capacity all the time ready to support the output load in case of AC source failure Although the principle and operation of a UPS seems simple and straightforward the requirement for a reliable and intelligent UPS makes the design and manufacturing of a high power UPS one requiring advanced technology intelligence experience and most important consideration of the user interface Many years have been spent in designing the most rugged intelligent and reliable UPS for the market and a safe and convenient UPS for the user Choosing the best and most suitable UPS for a given application can be easy or difficult depending on the client s knowledge of key parameters The most obvious specification output power depends on the size of the load Often an allowance of 5096 more power is added to the present load requirement both for tolerance and for future expansion Another important issue is reliabilit
11. 2 on the 3R PCB and the following examples and diagram Example 1 If two contacts for BACK UP are required Switch on SWR2 6 amp SWR2 8 and then both CNR19 amp CNR15 will close when the unit goes to back up Example 2 If one contact for OVL amp FAULT is required Switch on SWR2 2 amp SWR2 3 and then the CNR15 will close when either OVL or FAULT condition happens Of course CNR17 will close when OVL happens and CNR13 will close when FAULT happens 6005 184 Rev A RELAY CNR12 INVON RELAY CNRI7 OVL RELAY CNRIS FAULT RELAY CNR16 ss RELAY CNR14 BYPASS RELAY CNR19 BACKA 7 RELAY CNR20 BATL a 3 c RELAY CNR15 cOM 22223 22 2 7 2 2 DB9 Connection Four RS 485 and one RS 232 are provided to communicate with more sophisticated option modules Each connector is especially dedicated to one type of external module The following are some connection examples of optional modules CNR21 RS 232 lt UPSCOM Software for PC Monitoring SNMP Card CNR9 RS 485 DCMAN Battery Monitoring Module CNR10 RS 485 lt UPSCAN Remote Control Panel CNR12 13 14 15 17 18 19 RS 485 UPSCALL Auto Dialing Module CNR11 for transferring RS 485 into RS 232 Page 20 of 26 2 8 Operation Mode 2 8 1 BYPASS P d RESERVE Us RECTIFIER m AC SOURCE 6005
12. DC fuse over temperature bypass breaker on or emergency stop Since these LEDs are located behind the transparent window the user can see them clearly without opening the door D Audible buzzer alarm The user should not be expected to watch the UPS all the time Therefore when abnormal conditions occur an audible sound should be emitted to warn the user to check the status of the UPS The alarm buzzer will beep under any one of the following conditions INVERTER IS OVERLOADED 211096 beep once 3 seconds 212596 beep once second 215096 beep twice second BACK UP 2320VDC beep once 3 seconds lt 320VDC beep twice second lt 295VDC no beeping INVERTER IS SHORT CIRCUITED beep continuously FUSE BROKEN beep continuously HEAT SINK OVER TEMPERATURE beep continuously HIGH DC SHUTDOWN beep continuously BYPASS ON STOP beep continuously E Bypass LED This LED will light when the maintenance bypass breaker is closed When the maintenance bypass breaker is closed the inverter cannot be switched on and will stop immediately even when inverter is already running F Reserve LED This LED will light when the reserve breaker is closed and there is AC power supply present at the reserve terminal Page 17 of 26 6005 184 Rev G Rectifier LED This LED will light when the rectifier is operating normally meaning the rectifier Mains are within the range specified the rotation sequence of three pha
13. Normal operation with batteries connected provides clean stable regulated and uninterrupted power to the load free from any spikes and surges Therefore the UPS can be regarded as a perfect AC power source limited in back up time under mains failure only by the capacity of the batteries 6005 184 Rev A Page 23 of 26 TO LOAD 2 9 Options 2 9 1 2 9 2 2 9 3 2 9 4 2 9 5 2 9 6 2 9 7 2 9 8 2 9 9 2 9 10 6005 184 Rev A Software for PC Monitoring UPSCOM UPSCOM is a hardware software combination installed on a PC to monitor multiple UPSs with DB9 connection in series The connector on the UPS s side is RS 485 for long distance transmission therefore an RS 485 RS 232 adapter hardware is required to modify the signal The software and hardware together form a package called UPSCOM See the UPSCOM specification for further information Input Transient Voltage Surge Suppressor TVSS TVSS is a DIN rail mounted device connected to the Inverter input Its plug in phase modules are easily replaceable The device contains energy absorbing components and has a two stage protection When a protection component is damaged by absorbed transient the module will display a flag indicating a need for replacement Web SNMP Card This option is a web enabled monitoring device for a unit with Internet or network connection The SNMP Web card can monitor the Inverter on the network through a standard web
14. TECHNICAL GUIDE SPECIFICATIONS POWER WAVE 4 Three Phase 60 to 160kVA UL924 Central Lighting Inverter POWER Also available up to 500 kVA 1 0 GENERAL 1 1 1 2 SCOPE Central Lighting Inverter specification defines a high reliability three phase on line True Galvanic Isolated UPS double conversion digital signal processing high frequency pulse width modulated PWM system utilizing IGBTs It shall be designed to provide high quality regulated and conditioned AC power to all lighting loads at all times The unit shall be specifically designed to meet UL 924 for emergency lighting applications and provide 90 minutes of battery back up It shall be suitable for all lighting loads including any combination of electronic and security system power factor corrected self ballast Fluorescent Incandescent Quartz Re strike Halogen HID and HPS during emergency backup System shall be operating for the minimum of 90 minutes with 10096 load Upon return of the normal AC utility line system shall return to normal mode automatically without any interruption of power to the load The charging system shall recharge the battery within UL 924 requirements The lighting inverter uses industry distinctive small footprint cabinet design allowing for equipment installation in limited spaces STANDARDS The Inverter shall comply with the following standards A ETL Certified per UL1778 UL924 CSA STD C22 2 NO 07 3 0 B ETL Cert
15. TTERY Cab D D D 2D 2D 2D 3D 4D Batt 2x29 2X29 2X29 4X29 3X29 4X29 FRONT TERMINAL Qty a 29 gt d 58 58 58 116 87 116 BATTERY Cab D D D D 2D 2D 2D 3D 3D 4D D Cabinet dimensions 51w X 70h X 30 5d TABLE 2 82 el al al al al el el el el sl sl el el el slelelsleslel alel elele 8 23 g sssssaasssssssssssssssss sss e 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 8 S 8 8 SN z 8 2 3 3 sls 77 a 3 3 3 gt 09 S S S S S 2 2 2 s 2 2 S S 8 2 2 8 2 8s s S R 2 e s S 5 5 z e e 2 s 5 3 x g 8 g 8 515 5 Z a 3 E S S 3 2 5 S 5 31 3 81 218 B S 3 z 85 amp 5151 3 Sl 8l 8l 51 51 5 Sl sl 21 SI xi sisi 1515 3S 5191515 l 2 6 Components Description 2 6 1 Rectifier 6005 184 Rev A Page 9 of 26 INPUT il The main function of a rectifier is to convert the AC input to DC power and supply it to the inverter The inverter then converts the DC power to AC power for the load The UPS use the DC power to charge the batteries as well which is the most efficient method of charging REC TIFIER AC BREAKERINDUC TOR INPUT dio eee CAPACITOI 6 PULSE FULL CONTROL RECTIFIER UPS units 60KVA to 100KVA shall use 6 pulse fully controlled rectification optional 12 pulse An inductor is added before the rectifier to improve
16. ces shall be sealed All relays shall have dust covers All incoming parts modular assemblies and sheet metal shall undergo detailed receiving quality inspection 2 2 3 Factory Testing Every unit shipped will have completed a documented functional test of the Inverter module and a battery system including a battery discharge test A copy of the test report shall be available upon customer s request 2 3 Operation 6005 184 Rev A The system shall utilize High Frequency Pulse Width Modulation digital signal processing for control and monitoring The system shall have the capability of operating in 2 modes Double Conversion mode through inverter for supporting the critical load at all time with no switching during a power outage or Green mode through static switch for better efficiency with fast transfer time less than 2 milliseconds and compatibility with all type of lightings The system s automatic overload and short circuit protection of the inverter in normal and emergency operations shall consist of 150 momentary surge capability for 30 seconds and 110 12596 overload for 15 minutes The system protection shall also include a low battery voltage disconnect to prevent damages to the battery bank The system shall supply a clean computer grade sinusoidal output waveform with less than 296 total harmonic distortion at full rated load Dynamic brownout protection will maintain the desired voltage without continuously switching to batter
17. ent Happen 2 7 2 1 Dry Contacts 8 terminals of dry contacts are provided These terminals are normally open non conducting When an event occurs the terminal will close conduct Maximum contact rating is 16A 250VAC 16A 30VDC The events are shown below INVON Closed whenever the inverter is on open when the inverter is off OVL Closed whenever the UPS is overloaded FAULT Closed when the UPS encounters a fault condition such as high DC shutdown short circuit fuse over heat overload shutdown emergency stop inverter abnormal bypass on shutdown The contact is latched until manual reset off switch or 30 seconds after the fault condition is removed Page 19 of 26 TO INTERN CIRCUI SWR2 DIP SWITCH ON 3R PCB SS Closed when the inverter static switch is conducting open when the reserve static switch is conducting The two static switches will never conduct simultaneously BYPASS Closed when the maintenance bypass breaker is closed open when the breaker is opened BACK UP Closed when the inverter running is being backed up by the battery BATL Closed when the inverter is using battery power and the batteries are about to be exhausted COM This contact can be configured as the OR result of the signals described above SWR2 1 dip switch pin 1 SWR2 7 dip switch pin 7 can select one of the seven signals described above and SWR2 8 is the COM enable switch Please refer to the dip switch of SWR
18. ession The UPS shall employ an EMI filter to meet the international EMC limits Therefore very low noise is emitted and no interference is supplied to other equipment connected to the same AC Source Ruggedness The rectifier shall employ phase control technology to regulate the DC bus voltage This is the most efficient method to charge the batteries High frequency design The inverter shall use high frequency high efficiency IGBT PWM methodology to convert the DC power to AC power therefore reducing the number of components improving reliability reducing the size and weight of UPS while improving performance and minimizing acoustic noise Plug amp Play Modular design The system shall use module power circuit pluggable into slots in the UPS for ease of maintenance and troubleshooting Cold start function The UPS shall start without an AC source with battery power only By adding current limit circuitry to prevent large inrush current blowing the battery fuse and damaging the DC capacitors when batteries are connected to an empty DC bus before the DC bus is energized Multi CPU design The UPS shall employ several CPUs in the control circuit and critical functions design with parallel redundancy to improve reliability Therefore in case of one CPU failure the other CPUs keep the UPS operational and the output AC is not affected Protection against misuse The UPS shall be designed with breaker on off sensor power s
19. ies in low voltage situations up to 1596 The system shall maintain output regulation of less than 1 at all operating condition except overload and short circuit The system shall be able to protect its self from internal over temperature condition in the event of internal cooling condition and issue an alarm under such condition Page 2 of 26 The system shall consist of circuitry including an automatic multi rate software controlled charger self diagnostic programmable system testing capabilities a microprocessor controlled diagnostic display panel capable of audible alarms and visual displays of all alarm and inverter a DC to AC converter inverter a battery charger that meet UL 924 standard AC input breakerS and DC fuses for protection a battery bank sized for the system s runtime requirements at full rating and an RS232 communication interface The system shall include a user programmable monthly and yearly battery test scheduling and report printing capability for UL924 compliancy 2 4 Technical Specification 2 4 1 AC input Specifications Input voltage range 208 120V 15 or 480 277 15 Input Frequency 50 60 Hz 7 Input Power factor 0 8 PF Power walk in time 20 sec from 0 to 10096 Input current harmonics o 33 for 6 pulse rectifier unit o 15 for 12 pulse rectifier unit o 9 input filter option is available 2 4 2 Battery Specification Battery type Maintenance free sealed lead acid Standard
20. ified to UL 924 Emergency Lighting and Power Equipment Auxiliary lighting and Power Equipment D FCC rules and regulations Part 15 subpart j class A E NEMA PE 1 F NFPA 101 Life safety code G ANSI C62 41 IEEE 587 6005 184 Rev A Page 1 of 26 2 0 PRODUCT DESCRIPTION 2 1 APPROVED MANUFACTURERS AND PRODUCT DESCRIPTION 2 1 1 Approved Manufacturer The Inverter shall be an Emergency Central Lighting Inverter and shall be manufactured by ON LINE POWER INC 5701 Smithway Street Commerce CA 90040 Phone 1 800 227 8899 Fax 323 721 3929 Power Service 1 800 797 7782 2 2 QUALIFICATIONS AND QUALITY ASSURANCE 2 2 14 Manufacturer s Certification A minimum of twenty years experience in the design manufacture and testing of solid state Inverter is required The manufacturer shall specialize in manufacturing of on line double conversion high frequency Inverter modules specified in this document The manufacturer shall hold a current ISO 9001 2000 certification and shall design the units in accordance with internationally accepted standards 2 2 2 Materials and Assemblies All materials and parts in the Inverter shall be new of current manufacture unused except for the purpose of factory testing All active electronic components shall be solid state and designed as to not exceed the manufacturer s recommended ratings and tolerances for ensuring maximum reliability All IGBTs and other semiconductor devi
21. is being set N Down key This is a LCD control key It is for moving the cursor one item downward when items are being selected or for changing the number character backward when data or parameter of the UPS is being set Enter key This is LCD control key It is for changing backward to the previous page and also for confirming the number character item is selected P Inverter on switch This is an inverter control switch When this key is pushed with the control key simultaneously the inverter will be switched on Page 18 of 26 2 7 2 Inverter control switch This is an inverter control switch When this key is pushed with the inverter on key simultaneously the inverter will be switched on Similarly when this key is pushed with the inverter off key simultaneously the inverter will be switched off Thus this key is a guard for mistaken key strokes R Inverter off switch This is an inverter control switch When this key is pushed with the control key simultaneously the inverter will be switched off Communication All interfaces are connected from 3R PCB See the figure below CNRIG SWR2 3R PCB 3 4 20 CNR enris NR CNR19 CNRI4 CNRIS CNR CNR21 CNRIO CNRIIL CNRS CNR9 R5232 RS485 RS485 RS485 RS485 etel lere ere ale Soe eee pp D AD ae rs EUG de D 5 2 lt tn 6005 184 Rev A Short When Ev
22. n circuitry to protect the inverter A robust snubber is added to suppress the spikes and noise oversized semi conductor fuses are provided and ventilation is maximized The result of this design is a more rugged reliable and high efficient inverter At the same time the inverter can sustain overload and high peak current drawn by the load Additionally a longer MTBF is achieved 2 6 3 Static Switch 6005 184 Rev A Page 12 of 26 22 aT mel E RESERVE MODE 2 2 INVERTEB H E gt INVERTER MODE The static switch is composed of two pairs of SCRs connected back to back The switch can transfer the load from reserve to inverter or from inverter to reserve without losing power at the output Therefore it is a very important portion of a UPS Detection circuitry is added to the control circuit to achieve zero dead time transfer Extra detection logic is employed to control when the static switch should transfer For example when output is short circuited under normal mode operation the UPS detects the short circuit and stops the inverter The static switch will not transfer power to the reserve circuit which might damage the reserve breaker In case of an overload the UPS will stop the inverter after a period the inverter can endure and then transfer the load to the reserve circuit since the overload capability of the static switch is higher than the inverter The transfer action
23. nded beyond the normal Redundant power supply A supplemental power supply is added to provide redundancy for supplying power to the static switch so that there will be AC output no matter what happens to the UPS Options refer to detail for this section Model Number Refer to Table 1 Battery Table UL924 90 Minutes Refer to Table 2 Input Output protective devise rating and current calculation and floor loading Refer to Table 3 Page 6 of 26 MODEL NUMBERS INPUT OUTPUT kVAIKW MODEL NO VOLTAGE VOLTAGE 208Y 120 208Y 120 ny PWO10BOSATT3 208Y 120 PWO10HO9ATT3 480Y 277 480 277 208Y 120 208Y 120 PWO20BO05ATT3 Consult Factory for application TABLE 1 6005 184 Rev A Page 7 of 26 90 MINUTES BATTERY CONFIGURATION PARTNO 7050 7050 7050 7050 7050 7050 7050 7050 7050 7050 384 385 386 387 388 389 390 391 392 393 100KV 160KV KVA 10KVA 20KVA 30KVA 40KVA 50KVA 60KVA 80KVA 120KVA KW 8KW 16KW 24KW 32KW 40KW 48KW 64KW 80KW 96KW b CB FUSE 30A 70A 100A 125A 175A 200A 250A 300A 375A 500A MAX DC CURRENT 29 2A 58 5A 87 7A 116 3A 145A 175A 232A 289A 347A 463A DC VOLT 348V 348V 348V 348V 348V 348V 348V 348V 348V 348V STANDAR Batt zg 2X29 2X29 3X29 3X29 4X29 5X29 3X29 D Qty 58 58 87 87 116 145 87 BA
24. ses is correct the rectifier breaker is closed and no high DC voltage is on the bus H Back up LED This LED will light when the UPS is in back up mode This is also as the indicator for battery test result If the battery test does not pass this LED will flash even if the UPS is not in back up mode to prompt the user to change the batteries I Inverter LED This LED will light when the inverter is switched on indicating whether the inverter is running or not J Inverter SS LED This LED will light when the inverter static switch is turned on and the reserve static switch is turned off i e the load is supplied from the inverter Usually this LED will light 7 seconds after the inverter is switched on K Reserve SS LED This LED will light when the reserve static switch is turned on and the inverter static switch is turned off i e the load is supplied from the reserve Since the reserve static switch and inverter static switch will never both turn on simultaneously the Inverter SS LED and the Reserve SS LED should never both be lit simultaneously L Output LED This LED will light when there is AC power present at the output terminal This is an important indication to the user at to whether AC is available at the output or not M Up key This is a LCD control key It is for moving the cursor one item upward when items are being selected or for changing the number character forward when data or parameter of the UPS
25. sidering installation location or additional seismic brackets as an option 2 9 12 Delta connection 2 9 13 Dual Input 2 9 14 Seismic Bracket 2 9 15 Factory set Green Mode 2 10 Mechanical Design and Construction 2 10 1 Enclosure All system components shall be housed in a single floor mounted small footprint freestanding NEMA 1 enclosure The cabinet should have front access only with two doors and the depth of no more than 31 5 inch up to 320kva only allowing easy component reach from the front The enclosure shall have modular design for clear and accessible layout Cabinet doors shall require a key for gaining access Front access only shall be required for safety and expedient servicing adjustments and installation The cabinets shall be structurally adequate and have provisions for hoisting jacking and forklift handling 2 10 2 Construction Only quality unused material shall be used to build the unit under strict observance of standards and quality workmanship The cabinets shall be cleaned primed and painted IBM pearl or equivalent The unit shall be constructed with rigorously tested burned in replaceable subassemblies Only two electronic subassemblies heat sink assembly with IGBTs and drivers and control PCBA shall be used for maximum reliability and simple servicing All printed circuit assemblies shall have plug connections Like assemblies and like components shall be interchangeable 2 11 Replacement Parts Parts
26. t KVA and harmonic current drawn is minimized fulfilling the worldwide energy saving requirements The harmonic current can be further lowered by adding harmonic filters factory installation available The total harmonic current can be reduced to approximately 9 Page 11 of 26 IGBT INVERTER The inverter is composed of IGBT inductor capacitor snubber control circuitry and protection circuitry The inverter converts the DC power from the DC bus to AC power to supply the output load The UPS uses IGBT technology which switches at frequencies beyond the audible range therefore producing no audible noise The UPS uses voltage regulation circuitry to limit the voltage variation within 1 Special compensation circuitry is added to eliminate the output distortion Every component is oversized to accept the wide DC input range from 285 to 420VDC so that the output waveform remains sinusoidal throughout the range With the aid of dynamic feedback loop the inverter will keep a sine waveform even under non linear load An independent inverter is used for each phase Although it is more expensive each inverter has its independent feedback so that the voltage is unaffected when load is added to the adjacent phase producing excellent voltage regulation under 100 unbalanced load The IGBT is operated in its optimal condition to obtain best efficiency so as to minimize the power cost of the user The UPS shall use redundant protectio
27. t and output terminal blocks shall be provided for easy field wiring of Inverter and battery cabinets 2 18 Factory Startup Provides a factory service representative to perform the initial startup of the Central Lighting Inverter System 2 19 Drawings and manuals Drawings and manuals supplied with each unit shall include Complete set s of shop drawings showing physical dimensions mounting information and wiring diagrams Installation Manual s with complete instructions for locating mounting interconnection and wiring of the system User Manual s outlining complete operating and preventive maintenance procedures 2 20 Batteries shall be shipped separately 2 21 Installation The Central Lighting Inverter shall be installed in accordance with all appropriate manufacturers installation instructions and in compliance with all appropriate codes 6005 184 Rev A Page 26 of 26
28. the power factor smooth the current waveform and eliminate the harmonic current The control circuit regulates the DC bus within 196 Soft walk in circuitry approximately 20sec and current limit circuitry is used to prevent over current or instantaneous surge current Extra under voltage and over voltage protections are added to improve reliability and to shutdown the rectifier in case of abnormal conditions The DC bus is adjustable to fit different types of batteries The power component used in the rectifier is specially selected to handle extreme high voltage and high current The rectifier is designed to operate under a wide range of AC input from 177 to 300VAC to operate under the poor power conditions found in some areas PHASEHIFT TRANSFORME DC REC TIFIER OUTPU BREAKERINDUC TOR O CAPACIT 12 PULSE FULL CONTROL RECTIFIER 6005 184 Rev A Page 10 of 26 6005 184 Rev In order to further improve the power factor and reduce harmonic current drawn by the rectifier UPS at 120KVA and above use the 12 pulse full controlled rectifier The total current harmonic current can be reduced to around 1596 and power factor improved to over 0 8 A phase shift transformer is added to achieve this performance The input inductor is retained also to obtain the best result Although this results in higher cost the unit is much more reliable and rugged Users do not need to increase the input breaker and cable sizes since inpu
29. uit state FUSE OVER TEMP SD inverter shutdown due to either fuse broken or over temperature condition Page 15 of 26 6005 184 Rev INVERTER FAIL SHUTDOWN inverter shutdown due to inverter output voltage too low BYPASS ON SHUTDOWN inverter shutdown due to bypass breaker being closed while the inverter is running HIGH DC SHUTDOWN inverter shutdown due to overly high DC bus voltage condition while the inverter is running OVERLOAD SHUTDOWN inverter shutdown due to overload of the inverter for a period over that which the inverter can endure will restart 7 seconds after overload removed 70 LOAD load connected to the output is at or over 70 of the UPS rating 110 LOAD load connected to the output is over 11096 of the UPS rating 125 LOAD load connected to the output is over 12596 of the UPS rating 150 LOAD load connected to the output is over 15096 of the UPS rating RESERVE AC FAIL reserve AC magnitude is out of range RESERVE FREQ FAIL reserve frequency is out of range BATTERY LOW DC bus or battery is lower than 320VDC low battery shutdown is approaching BATTERY LOW SHUTDOWN inverter shutdown due to DC bus or battery lower than 295VDC lower than the acceptable DC voltage of the inverter RECT AC FAIL rectifier AC magnitude is out of range ROTATION ERROR rectifier AC phase rotation is incorrect RECTIFIER SHUTDOWN rectifier shutdown due to DC bus too high over 445VDC
30. upply sensor etc to prevent harm to the UPS caused by user error Page 5 of 26 2 5 1 2 5 2 2 5 3 6005 184 Rev Accepts wide input range The UPS shall accept wide input range so that it can work effectively under an unstable AC source All of the input components used are specifically selected to handle extreme high voltage and high current Intelligent charger The UPS shall automatically recharge boost charge the batteries every time the batteries are depleted to a voltage level equal to 2V Cell Thus the batteries can be restored to full capacity as soon as possible and made ready for the next back up requirement In order to keep the batteries in the best condition the UPS will boost charge the batteries for several hours selectable automatically every month To avoid over charging the batteries boost charge will stop when the ambient temperature is over 35 C 95 F Intelligent battery test The batteries shall test after every boost initiated by battery discharge or by the monthly boost charge cycle This shall be done without interrupting the operation of the rectifier preventing the risk of output AC failure in case of a defective battery and inform the user of the battery condition so that action can be taken before the full capacity of the batteries is needed MTBF of fans are extended Fans used to cool the UPS are designed to slow down under light load so that the life expectancy of the fans is exte
31. y The prime aim of a UPS is to protect your load Therefore the UPS should be much more reliable than the AC source An unreliable UPS may suffer the problem of frequent break down even more frequent than AC failure and the cost of repair may become more than the cost of the unit itself Generally there are four different modes of operation the NORMAL OPERATION MODE the BACK UP BATTERY MODE the RESERVE MODE and the MAINTENANCE BYPASS MODE These are explained below Page 21 of 26 2 8 2 Normal Operation Mode BYPASS RESERVE x ke lt lt CTIFIE 4 c RECTIFIER c bacc tache A 11 EC E RECTIFIER 1 INVERTER at ISOLATION Pe TRANSFORMER SIR The rectifier converts the AC input to DC power to supply the inverter and charge the batteries simultaneously All the fluctuations surges and spikes of the AC input are removed during AC to DC conversion Therefore the AC supplied by the inverter is clean and stable 2 8 3 Back up Mode BYPASS RESERVE SOURCE RECTIFIER SN EA E 9 2 71 c RECTIFIER INVERTER ISOLATION TRANSFORMER hi fid Since the batteries are connected directly to the DC bus when the AC fails the batteries change immediately from receiver to donor supplying energy to the inverter instead of receiving energy from the rectifier The output AC is not interrupted Therefore the load connected to the output is protected 6005
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