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M4103_Borealis_8-48Kw_Service_Manual V3.1 2012-06

1. iS G YEL o e MAIN CONTROL lt 8 e BRN RED NE lt BLK CNA9 6 BLU BRN CNTe CNTe CNTe 3R COMMUNICATIONS 5 BLU 5 RELAY INTERFACE EE 25232 25485 INVERTER PHASE INVERTER PHASE INVERTER PHASE CONTROL CONTROL CONTROL R PHASE 5 PHASED T PHASE 2 TD pd 2 MODULE pa Cares Gara Geo raeo TET 25 dM ax 7 5 m gt m 3 m Detailed drawing of PCB Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 36 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 5 Rectifier SNUBBER x CNS2 CNS4 R Qu 5 as FEB 4 RECTIFIER MODULE DRIVER RAP 2 7 6 Detailed drawing of Rectifier System M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 37 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE I
2. KW Rating 8 12 16 24 32 40 48 INVERTER DC Input Range 285 415VDC Wave Form Sinusoidal 120 208V 277 480V 347 600 3 Phase Output Voltage Adjustable 4 Wire Crest Factor 331 Output Power Factor 0 8 Voltage Regulation 10096 Unbalance Load Frequency Lock Range 45 55 Hz 55 65 Hz 50 60 Hz 0 1 Hz Static 1 o _ Output Jo shen ee Ns 3 recovering to within 1 in 1 cycle 0 _ 2 m ps SERO 2 recovering to within 1 1 cycle 100 unbalanced load Ph N baia Phase Shift Under 100 o Unbalance Load Pepe THD Linear Load 2 96 11096 CONTINUOUS 110 12596 15 min Overload 125 150 10 min gt 150 60 sec Efficiency 100 Load 93 93 93 93 93 5 93 5 94 Maximum Output Wattage kW 8 12 16 24 32 40 48 STATIC SWITCH Voltage Range 20 of input voltage Line to Neutral Frequency Range 45 55 Hz 55 65 Hz Efficiency 99 5 Transfer Mains gt Inverter 0 ms Time Inverter gt Mains 0 ms 10096 30 sec Overload 300 pem Isolation With Output YES M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 73 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTE
3. 22 5 5 72 Battery Backup Units BBU 76 Contact IN TOMALION lesin 78 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 ix WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 1 Introduction WARNING The user of this manual must be factory trained and authorized to service three phase Always On ELI systems This manual is to be used in conjunction with the Operators Manual This manual is designed to aid in the understanding and identification of the major components It will provide general information and layout of each major component and what assemblies are involved in the functionality of that specific component 1 1 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
4. 16 4 4 From Manual Bypass to Inverter 2 17 4 5 Manual Battery Test oett 17 4 6 Battery Condition 17 5 The ECD BISDIA 18 5 1 0 Main Mens sooo eq et teda en a 18 52 Menu 1 Select Rr eibi ene 19 5 3 Menu 2 Status Warning Menu 19 5 4 Menu Real Time Data sss 21 5 5 Menu 4 Historical Event 23 5 6 Menu 5 Parameter Setting Menu 24 6 Physical TODOIOGQY e eb be rr eiua 28 7 Electrical Layout Drawings 32 7 1 Single Eine 32 7 2 Topology Drawings ues tas ORTI 33 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 viii 8 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 3 IN OR BO DIAGTAMI mt dt sade autein 35 7 4 PCB Mod l noenee Quan sir 36 7 5 cni 37 7 6 Inverter odas to tec b I ma t M Men 38 7 7 Static OWNER esl dom sce
5. 39 7 8 Auxiliary Power Supply err 40 Tro bleshootIRga u Si G N skalla 41 8 1 Main Control 41 8 2 Power Supply 3B PCB oe pa NS 44 8 3 Rectifier Control Circuit 3C 46 8 4 Inverter Phase Control 48 8 5 Communications Interface SR 50 8 6 Warning LED s and Switches SW 32 8 7 ECD DISplIay o NI SL u al 52 8 8 Mimic Diagram 3L PCB nn a 52 8 9 Status LED s and Audible Alarm 52 8 10 Inverter Module eoe e Q u aes ag vote m e E Ce PR RIEN Ee 53 8 11 Rectifier Module 56 8 127 Statio ois te 59 BOARD FAULT DIAGRANS 62 STATUS INDICATOR TABLE II l Na u 70 BOARD LED INDICATION TABLE 71
6. SO O O O O O O O O O V O O O O O O O O O jO O O O O O O O jO IO O x O O O O O O xO O O O O O O O O gt x O x O O O jO gt gt INVERTER MODULE R INVERTER MODULE S INVERTER MODULE T STATIC SW MODULE R STATIC SW MODULE S STATIC SW MODULE T 20 20 20 Oo o o 25 20 20 20 3A MAIN CONTROL INVR 3A MAIN CONTROL INV S 3A MAIN CONTROL INV T 3A MAIN CONTROL OTF C REC CONT REC ENABLE ALL PCBs POWER STATUS 0 0 0 20 1 G R G G G Push OFF Button to reset Alarms 0 indicates faulted phase 1 indicates faulted phase M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 11 BOARD LED INDICATION TABLE NORMAL ABNORMAL PCB FUNCTION LOCATION LED m
7. P cree Sea es I O e opo 0 4 Always On Figure 7 2 Topology 3 Phase ELI 6 Pulse Rectifier M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 33 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER BYPASS 4 gt PAS RESERVE j um OUTPUT a DH 9 0 1 ettos AUTO TRANS RECTIFIER 2 lor zs E CO miT 3 ry 5 d ol SN PSAL RE K 3 TOX L ok o AS 221 mmm T Pes Figure 7 3 3 Phase ELI 12 Pulse Rectifier BAT POS M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 Topology 3 Phase ELI Input 3PH 4W Output 3PH 4W Zero Degrees Phase Shift Always On 12 Pulse Rectifier 34 7 3 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER
8. 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 e INVERTER FAIL INV SHUTDOWN inverter has shutdown due to inverter output voltage below tolerances e 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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
9. 8 14 Layout of one phase of the Inverter Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 55 AC DUPUT WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 11 Rectifier Module This is a Pluggable Module which contains the high power devices for the rectifier charger The rectifier converts the power from the AC utility to regulated and conditioned DC power which is used to charge the batteries and supply the DC Bus The rectifier can be configured as a 6 pulse or 12 pulse rectifier system The rectifier is comprised of a Rectifier Driver 3S PCB high powered SCR s and other monitoring and protection components RECTIFIER AND STATIC SWITCH MODULE NV 33AD 1 D P D P PSR 5 Figure 8 15 Location of Rectifier Module in the 8 to 48KW ELI System M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 56 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Static Switch S Phase 6 pulse Rectifier Figure 8 16 Picture of Rectifier and Static Switch Module for the 8 to 48KW ELI systems M4103 Borealis 8 48Kw Service Manual
10. 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 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 M4103 Borealis 8 48Kw S
11. M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 2 Theory of Operation 2 1 AC UTILITY General Topology MANUAL s BYPASS AUTOMATIC BYPASS m em t a TVSS FILTER RECTIFIER INVERTER a BATTERIES d Figure 2 1 General Block Diagram TO LOAD TVSS Filter ISOLATION TRANSFORMER 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 bypass Full maintenance bypass Emergency power off EPO connection Communications interface SNMP Adapter for network communications and monitoring Input power walk in Front cable connections Output isolation transformer Optional Features 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 Generally there are fo
12. in 1 9 2 LED R1 Figure 8 10 3R PCB Communications Interface Table 8 5 LED Operation for the 3T PCB NORMAL ABNORMAL PCB FUNCTION LOCATION LED LED 27 SOLUTION PCB LED ae Description Description Illumination Illumination T Ensure cable connections are secure Communication Interface 3R Interface PCB Module LED R1 Yes PCB has power No communication falle and correctly attached Replace the board M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 51 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 6 Warning LED s and Switches 3W PCB 8 7 LCD Display 8 8 Mimic Diagram 3L PCB 8 9 Status LED s and Audible Alarm 3AG PCB These PCB s make up the local Operator display and control interface Figure 8 11 Location of Display PCB s in the PCB Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 52 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 10 Inverter Module This is a Pluggable Module which contains the high power devices for the inverter The inverter converts the power from the DC Bus to re
13. 9 10 113A 3R x x Figure 7 9 Detailed drawing of the Aux Power Supply M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 40 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 Troubleshooting 8 1 Main Control 3A PCB The Main Control PCB monitors and controls all the major components within the ELI system Through the various monitoring devices and PCB s mentioned later in this manual it provides all the control signals synchronizing signals and various conditions to the ELI system and Operator interfaces Figure 8 1 Location of 3A PCB in the PCB Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 41 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER LED A1 LED A2 LED 4 B 11 JA ad 74 4 TL Md T ee El uir pd y Ez LED A6 Figure 8 2 3A PCB Main Control LED A4 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 42 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR
14. LOAD LED will also be lit Manual Battery Test 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 Battery Condition Test To be performed by service personnel Consult service manual for more information M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 5 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 5 1 Menu 0 Main Menu MODEL I S 345678901 ID 01 50KVA 1 120 208V 60HZ 120 208V 60HZ 2007 01 01 TUE 08 00 Figure 5 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 kV
15. VLC gs BATTERIES ie 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 5 2 6 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 RECTIFIER PFC DCFILTER AC BREAKER OUTPUT RECTIFIER 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
16. WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Figure 6 6 Figure 6 7 Figure 6 8 Layout view of the left side of the Layout view of the back of the Layout view of the right side of the system with the panel off system with the panel off system with the panel off M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 31 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 Electrical Layout Drawings 7 1 Single Line Drawing 10112 BYPASS e RESERVE NFB 3P INPUT 4W G 4103 Borealis 8 48 Service TO LOAD PANEL 3PH 4W Figure 7 1 Single line Drawing Manual V3 1 2012 06 22 32 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 2 Topology Drawings 3 Phase ELI 6 Pulse Rectifier Input 3PH 4W Output 3PH 4W Zero Degrees Phase Shift BYPASS 4q gt RESERVE jJ bh gt LKH 3 E 4 OUTPUT e OR d Ga 2 al O S AUTO TRANS RECTIFIER 3
17. 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 Ae 2 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 iv WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER A Safety Ins
18. 5 is reached by selecting PARAMETER SET on MENU 1 and access is only allowed if the correct password is entered See figure 5 6 2 The cursor is used to select which parameter the user would like to edit such as INVERTER ON OFF AUTO START ON OFF BOOST CHARGE DATE TIME and TEST BATTERY To select one of the different menu options move the cursor until it is pointing at the correct selection by press the UP 7 key or the DOWN key To confirm and select the menu option press the ENTER J key The INVERTER ON OFF option allows the user to activate or deactivate the inverter When selected the blinking display ON or OFF indicates the current status of the inverter To change the state of the inverter press the UP 7 or the DOWN key and confirm selection by pressing the ENTER 1 key INVERTER will be displayed if ON is selected or INVERTER OFF will be displayed if OFF is selected The AUTO START ON option is set to ON as a factory default setting Selecting the EXIT option blinking instead of pointed by cursor will return you to MENU 1 Figure 5 13 Password Menu Display M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 24 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRA
19. 815mm 32 0 1 600mm 63 0 1 600mm 63 0 920kg 2 024lbs 1 672 kg sq m 207 Ibs sq ft M4103 Borealis 8 48 Service Manual V3 1 2012 06 22 28 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Figure 6 3 N Front view of system with Door Open PCB E Module fully open and terminal strip cover off Figure 6 4 Front view of system with Door Open and PCB Module door open M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 29 815mm 927 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER I QNA 559mm 221 Figure 6 5 Front Side amp Top Views M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 30 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI
20. 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 Inverter LED This LED is lit when the inverter is supplying power to the load M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 12 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 LE
21. Inter PCB Diagram Inverter Driver Rectifier 6 Pulse 12 Pulse 3G Inverter Inverter Driver Driver 3S 3S Rectifier Rectifier Driver Driver T Phase mE LIN MICE Mc i i Warning LED s LCD arin deas and Switches Panel i Mimic i Diagram 3AG Rectifier 3W Control 3L 1 i Main Control 3R Communications i Interface I i R Phase i 3T Inverter Inverter Inverter Control Control Control 3 Z sassa usss m s M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 35 Figure 7 4 Connection diagram for the PCB Module Inverter Rectifier and Static Switch WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 4 Module 22 BRN G Y RED GRN BAT ET CNB2 LCNB7 r LCD PANEL 3B RECTIFIER CONTROL POWER SUPPLY WABNING STATUS g LED PANEL LED PANEL g amp SWITCHES amp BEEPER TD REC MODULE MIMIC PANEL CNC4 CNA8 T SS MODULE ay 9909
22. LED E SOLUTION PCB LED lumi Description Description uminated Illuminated Check 3T R phase ensure LED A1 No 3T R phase Yes R phase failure and cable connections are secure INV R working UPS shutdown and correctly attached Replace the board Check 3T S phase ensuring LED A2 No 3S S phase Yes S phase failure and cable connections are secure INV S working UPS shutdown and correctly attached Replace the board Check 3T T phase ensuring 3A Main Control PCB LED A3 No 3T T phase Yes T phase failure and cable connections are secure Module INV T working UPS shutdown and correctly attached Replace the board LED A4 Check 3G and ensure cable Overtemp Fault No 3G working Yes 3G has problem EE i oe ang OTF correctly attached Replace the board Check 3B and ensure cable LED A5 A6 PCB has no input connections are secure and 12VDCA Yes PGB nas power Ne power correctly attached Replace the board LED B1 B2 B3 Check fuse set behind PCB B4 holder and ensure cable B1 and B3 LED s of PCB connections are secure and 16VDCA PILES POB pas power Ne extinguished correctly attached B2 and B4 PCB 16VDCB Replace the board 3B Power Supply Module The system is LED B6 testing the Batt Test batteries LED B7 The system is Boost Charge Yes boost charging the batteries PCB has no input Ensure cable connections Rectifier Control LED C1 m power or input power Secure and correctly attached It is separated Rec
23. PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 2 8 Static Switch 2 9 RESERVE RESERVE E LOAD Loap INVERTER D INVERTER INVERTER MODE RESERVE MODE 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 remov
24. TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3B Board Fault UPS will not start up Once Reserve Breaker is closed 9 e all LED s on front display light up and LCD is non functional e Figure 9 2 3B Board Fault M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 63 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3CC Board Fault UPS will not start up Rectifer disabled No e DC Buss Figure 9 3 3CC Board Fault M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 64 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3R Board Fault No front panel display and no communications UPS starts up as per normal operation and inverter and rectifier function as per normal operation Figure 9 4 3R Board Fault M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 65 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3T Board Fault A UPS sys
25. cable connections are secure puse o All Yes PCB has power All No PEB di ar input correctly attached Replace the board M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 47 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 4 Inverter Phase Control 3T PCB This PCB acts as the interface between the Main Control PCB and each phase of the Inverter Module It relays the control signals and inverter drive waveforms from the Main Control PCB to the Inverter Driver 3G PCB within each phase of the Inverter Module It also monitors all aspects of the Inverter Module This information is then forwarded to the Main Control PCB as part of the control 8 7 Location of 3T PCB in the PCB Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 48 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 4 d Figure 8 8 3T PCB Inverter Driver Li F ms L 4 LED T1 LED T2 Table 8 4 LED Operation for the 3T PCB NORMAL ABNORMAL PCB FUNCTION LOCATION LUTION s PCB LED LE D Description Descrip
26. 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 2 7 Inverter LOW PASS SERIES FILTER 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 compensat
27. 22 19 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 15 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 274 row 170 OVERLOAD over 170 maximum capacity for the ELI system 150 OVERLOAD over 150 maximum capacity for the ELI system 125 OVERLOAD over 125 maximum capacity for the ELI system 110 OVERLOAD over 110 maximum capacity for the ELI system 39 row BATTERY LOW STOP Battery have been exhausted BATTERY LOW Batteries have passed the low voltage level and will soon be exhausted BATTERY BAD One or more cells have tested faulty BATTERY GND FAULT Battery cabinet not grou
28. A 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 T DOWN J ENTER keys the LCD will change to another screen M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 18 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 5 2 Menu 1 Select Menu Figure 5 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 opti
29. Always On Borealis Series Three Phase ELI System 8 KW 48 KW Service Manual 4103 Borealis 8 48 Service Manual V3 1 2012 06 22 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 insta
30. D 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 13 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRAN
31. ER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Static Switch Module Fault UPS starts up to full operation When inverter is turned off UPS output shuts down because of faulty static switch Figure 9 8 Static Switch Module Fault M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 69 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 10 STATUS INDICATOR TABLE Indicators xj Reserve Rectifier Inverter IP Breaker Fault 1 O Off R Red G Green Breaker ON Breaker 292 opp OFF Condition x On or Off REC AC FAIL 0 RESERVE FAIL 0 FUSE TEMP gt 0 OVERLOAD 0 HIGH DC 0 BAT LOW gt 0 BAT LOW STOP gt 0 FAULT 0 o 23 2 x INVERTER ON INVERTER SS SHORT CIRCUIT FUSE OVER TEMP SD INVERTER FAIL SHUTDOWN BYPASS ON SHUTDOWN HIGH DC SHUTDOWN OVERLOAD SHUTDOWN 70 LOAD 11096 LOAD 12596 LOAD 15096 LOAD RESERVE AC FAIL RESERVE FREQ FAIL BATTERY LOW BATTERY LOW SHUTDOWN REC AC FAIL ROTATION ERROR RECTIFIER SHUTDOWN HIGH DC BOOST CHARGE BATTERY TEST EMERGENCY STOP DATA LINE x gt x
32. INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 79 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Always On M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 80
33. ITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 12 Technical Specifications 8KW to 48KW 30 Input 30 Output KW Rating 8 12 16 24 32 40 48 RECTIFIER Input Voltage 208V 480V 600V 3 phase 3 and 4 wire G Input Range 180 750V Input Frequency 50 60 Hz 7 Input Power Factor lt 1 Normal Input Current A Based on 208VAC 33 49 66 99 192 165 198 Maximum Input Current A Based on 208VAC 99 83 125 160 200 250 6 PULSE 3096 12 PULSE 1596 putrenp Rp 12 PULSE WITH FILTER 996 Power Walk In adjustable 096 10096 20 sec Efficiency 99 Voltage Regulation 1 Ripple Voltage 0 5 BATTERY Battery Type Maintenance free Sealed Lead Acid No Of Cells 174 Voltage Range 295 410VDC Maximum Charge Current ADC 19 19 2y gt 99 Battery Low 320VDC Voltage Battery Low Stop 295VDC Voltage Boost Charge 410VDC Float Charge 396VDC M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 72 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER
34. MMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 3 Rectifier Control Circuit 3C PCB This PCB acts as the interface between the Main Control PCB and the Rectifier Module It relays the control signals from the Main Control PCB to the Rectifier Driver 38 PCB within the Rectifier Module It also monitors all aspects of the Rectifier Module This information is then forwarded to the Main Control PCB as part of the control loop Figure 8 5 Location of 3C PCB in the PCB Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 46 Figure 8 6 3C PCB Rectifier Driver LED C2 LED C3 LED C1 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Table 8 3 LED Operation for the 3C PCB NORMAL ABNORMAL PCB FUNCTION LOCATION m LED m SOLUTION PCB LED LED Illumination Description S rai Description Illumination PCB has no input Ensure cable connections are secure m power or input power correctly attached pa LED C1 Yes Rectifier Enabled No outside of operating Check the input power arameters 9C board for PCB Module p Replace te board option of 12 pulse A nsure
35. NTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 13 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 Battery Cabinet 3 Width 1321mm Depth 864mm and Height 1930mm Figure 13 1 3 Phase Battery Cabinet Layout M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 76 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 f
36. NTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Boost Charge Menu WARNING These settings have been preset by the factory to optimize the battery bank requirements Do not change settings unless factory or factory trained service personnel have been consulted Figure 5 14 Boost Charge Setting Menu Display This menu is reached by selecting BOOST CHARGE on MENU 5 This option allows the maintenance personnel to select the amount of boost charge required to maintain the batteries at their optimal performance Move the cursor up or down UP T and DOWN J key respectively and select the option by pressing the ENTER 4 key Figure 5 15 Boost Charge Setting Menu Display Program Settings AUTO BOOST MONTH controls the number of hours that the system will be boost charged every month This boost charging conditions the batteries and increases the life expectancy of the batteries WARNING These are preset options by the factory DO NOT CHANGE without consulting factory AUTO BOOST BATT LOW controls the number of hours that the system will be boost charged after the system has reached a low battery condition This boost charging recharges the batte
37. NVERTER 7 6 Inverter 3G INVERTER TO CNG1 DRIVER CNG6 PCB PCB MODULE CNG8 CNG3 TO Figure 7 7 OUTPUT Detailed drawing of one TRANSFORMER phase of the Inverter System AA SNUBBER B M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 38 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 7 Static Switch SAC RESERVE OUTPUT l m TO PCB 2 INVERTER TB DUTPUT Figure 7 8 Detailed drawing of one phase of the Static Switch System M4103 Borealis 8 48 Service Manual V3 1 2012 06 22 39 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 8 Auxiliary Power Supply SIFAN 180Vac ACPS 120Vac LLOUIPUT 9 4A 0 250 Vac SSPS 120Vac RESERVE 9 9 8A DC BUSS 519632 BATTV 2 1 6 3 4 UPPER FAN POWER SUPPLY 7 POWER SUPPLY LOWER FAN 6 8 3 120Vac 30Vac 519632 4 3 MAIN CONTROL 52 07 BOARD BOARD
38. OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Table 8 1 LED Operation for the 3A PCB NORMAL ABNORMAL PCB FUNCTION LOCATION LUTION HNG TIG a PCB LED E Description Description Illuminated Illuminated 3T R phase R phase failure Check 3T R phase ensure cable connections LED A1 No Aud Yes and ELI are secure and correctly attached 9 shutdown Replace the board 3S S phase S phase failure Check 3T S phase ensuring cable LED A2 No MORE Yes and ELI connections are secure and correctly attached 9 shutdown Replace the board 3T T phase T phase failure Check T phase ensuring cable Main Control Module LED No Yes and ELI connections are secure and correctly attached working shutdown Replace the board Check 3G and ensure cable connections are LED A4 No 3G working Yes 3G has problem secure and correctly attached Replace the board Check and ensure cable connections are All Yes PCB has power All No has no ipu secure and correctly attached A6 power Replace the board M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 43 8 2 Power Supply 3B PCB This is the main power supply for the PCB and is the interface between the Main Control PCB and the Battery supply It provides battery condition information to the Main Contro
39. P THE INVERTER The values selected value is flashing are increased by the UP T key and can be decreased by the DOWN key and confirmed by the ENTER 1 key If EXIT is selected blinking instead of pointed by cursor the screen will go back to the MENU 5 the PARAMETER SETTING menu M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 27 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 6 Physical Topology Figure 6 2 Front view of system with Door Open Weight H Height ELI Floor Loading 1 600mm 63 0 380kg 838lbs 864 kg sq m 177 Ibs sq ft 1 600mm 63 0 415kg 915lbs 943 kg sq m 193 Ibs sq ft 1 600mm 63 0 450kg 992165 1 023 kg sq m 210 Ibs sq ft 1 600mm 63 0 580kg 1 279lbs 1 318 kg sq m 270 Ibs sq ft 1 600mm 63 0 650kg 1 433lbs 1 477 kg sq m 303 Ibs sq ft 710kg 1 565lbs 1 614 kg sq m 330 Ibs sq ft Figure 6 1 Front view of system with Door Closed ELI Rating Dimensions KW W Width D Depth 8 559mm 22 815mm 32 0 12 559mm 22 815mm 32 0 16 559mm 22 815mm 32 0 24 559mm 22 815mm 32 0 32 559mm 22 815mm 32 0 40 559mm 22 815mm 32 0 48 1 100mm 43 25
40. R KW Rating 8 12 16 24 32 40 48 OVERALL CHARACTERISTICS Overall Efficiency 91 91 91 91 91 5 92 92 Operating Environment Temperature 0 40 C 32 104 F Humidity 0 95 non condensing Altitude lt 1500 m above sea level Maximum Heat Dissipation kW 1 2 1 2 1 3 1 9 2 6 3 9 5 Weight kg 250 275 300 400 480 550 680 Dimension HEIGHT mm 1600 WIDTH mm 559 DEPTH mm 815 Audible Noise lt 65 dBA AT 1 m Standards CSA Yes CE Yes EN50091 1 2 Yes FCC Part 15 Class A Yes Protections Short Circuit Rectifier Reserve Bypass NFB Lightning MOV EMC Filter Input amp Output Galvanic Isolation Between Input amp Output Data Display By LCD Yes Indications amp Alarms LED LCD Buzzer Yes Dry Contact Yes Battery Start Yes All specifications mentioned above are subject to change without prior notice M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 74 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Specification Table for Three Phase Inverters Model Size 8kW 12kW 16kW 24kW 32kW 40kW 48kW Output Powe
41. TA and OTHER DATA To select one of the different menu options move the cursor gt until it is pointing at the correct selection by press the UP 7 key or the DOWN key To confirm and select the menu option press the ENTER 1 key Selecting the EXIT option blinking instead of pointed by cursor will return you to MENU 1 Rectifier Data Menu Figure 5 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 2 configured systems The UP 7 or DOWN J key has no function in this menu The screen will return to MENU 3 when the ENTER 1 key is pressed Reserve Data Menu Figure 5 7 Reserve Data Menu Display M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 21 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER This menu is reached by selecting RESERVE DATA on MENU 3 The information p
42. TED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Table 8 8 LED Operation for the 3P PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LED D ipti LED D ipti SOLUTION LED Illumination Illumination Inverter output is within Inverter operating transfer Static Switch Driver Static Switch LED Yes normal parameters Ne from inverter has failed Replace the heard R S T Module is withi i LED P2 Yes Reserve output is within No Inverter operating transfer Replace the board normal parameters from reserve has failed m CNP6 CN s ss MUDULE P3 CRD 2625 6 Figure 8 20 Layout of one phase of the Static Switch Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 61 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 9 BOARD FAULT DIAGRAMS 3A Board Fault UPS will not start up Once Reserve Breaker is closed all LED s on front display e light up and LCD is non e functional 9 SEP Figure 9 1 3A Board Fault 62 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED
43. THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 e 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 e FUSE TEMP inverter has shutdown due to inverter fuse open or heat sink temperature above operating parameters e OVERLOAD an overload condition has occurred on the output e HIGH DC this LED will be lit as long as the DC voltage exceeds 430VDC e BAT LOW this LED will be lit as long as the DC voltage is lower than 320VDC e 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 e 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
44. TIERYLOW AP 7 RESAC FAIL BATLOW ce BERLIN NRR NRR WVSUDOW SUDOW SIC NERA O REFR INV S UIDOWN AC FAL 1 BATERY FUEE TEMP BATLOW SIOP a i ROR HGH DC BUSS 5 SHUTDOWN OVERDAD INV OVERLOAD 70 J BOOST 70 LOAD POs 110 BATERY INVERTER CONTROLS S 0881888 EMERGENCY 50 COMM af ACWE OFF LCD CONTROLS JPQ M Figure 3 1 Front Panel 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 M4103 Borealis 8 48 Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE
45. TY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 4 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 Make certain there is no foreign material left on inside or around the ELI Ensure all breakers and the battery disconnect switches are opened Ensure all loads are switched off Check that the input frequency matches the ELI s rated input frequency Check that the input voltage matches the rated input voltage e o gt o 4 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 batte
46. V3 1 2012 06 22 57 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Table 8 7 Operation for the 3S PCB NORMAL ABNORMAL PCB FUNCTION LOCATION LED mm LED SOLUTION PCB LED Description mt Description Illumination Illumination Ensure cable connections are secure If DC bus can be stabilized and correctly attached The expected the AC output is transferred to f Rectifier MTBF for this system is 3 000 000 3S Rectifier Drive Module the reserve automatically minutes If during operation it transfer Check input and rectifier breaker are to back up mode closed and input utility is present CNSe 51 CNS7 09 RECTIFIER 4 MODULE DRIVER SCRI ESNI s ess x T SCR Figure 8 17 Layout of Rectifier Module 6 pulse M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 58 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORI
47. ZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 12 Static Switch This is a Pluggable Module which is part of the Rectifier Module for the 8 to 48KW ELI systems containing the high power devices for the static switch The static switch monitors the inverter and output if a condition occurs inverter shutdown or problem condition it will transfer the output from the inverter to the reserve path automatically When the condition has been cleared the static switch will automatically transfer power from the reserve path to the inverter One phase of the static switch is comprised of a Static Switch Control PCB 3P PCB high powered naturally commutated SCR s and other monitoring and protecting components RECTIFIER STATIC SWITCH MODULE X3ADI SS PSR S Figure 8 18 Location of Static Switch Module in the 8 to 48KW ELI system M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 59 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Static Switch P1 LED 6 pulse Rectifier Figure 8 19 Picture of Static Switch and Rectifier Module for the 8 to 48KW ELI systems M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 60 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMIT
48. been selected confirm with the ENTER 4 key The CHARGE CURRENT can be roughly selected by the simple rule listed below CHARGE CURRENT SETTING 10 30 min battery back up LOW 30 min 1 hour battery back up MEDIUM gt 1 hour battery back up HIGH Selecting the EXIT option blinking instead of pointed by cursor will return you to MENU 5 Date Time Setting Menu Figure 5 17 Date Time Setting Menu Display This menu is reached by selecting DATE TIME on MENU 5 This menu allows the user to set the YEAR MONTH DAY HOUR MINUTE and DAY OF THE WEEK of the real time clock The display upon selection is the current time and day factory preset To change any to the variables move the cursor to the correct variable by pressing the UP 1 and DOWN V key the ENTER 4 key will confirm the selection Below is a list of the available variables YEAR 1998 2097 MONTH 01 12 DAY 01 31 internal calendar will correct it if 31 is entered to a 30day month HOUR 0 23 MINUTE 0 59 DAY OF THE WEEK MON TUE WED THU FRI SAT SUN M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 26 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START U
49. ce 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 vi WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 da
50. ctrically 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 Do not use this equipment for other than intended use M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 40 104 F Optimal battery life is obtained if the ambient temperatu
51. d 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 lt P 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
52. ed 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 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 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3 Front Panel E INVERERO mu wo RECTAC FAIL HGHDC RENE IRSE FREQ FAL MEH 3 5 5 SRTCIRCUT BA
53. ervice Manual V3 1 2012 06 22 11 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 e INVERTER IS OVERLOADED gt 110 beep once 3 seconds gt 125 beep once second gt 150 beep twice second e BACK UP gt 320VDC beep once 3seconds lt 320VDC beep twice second lt 295VDC no beeping e INVERTER IS SHORT CIRCUITED beep continuously e FUSE BROKEN beep continuously e HEAT SINK OVER TEMPERATURE beep continuously e HIGH DC SHUTDOWN beep continuously e BYPASS ON STOP beep continuously e EMERGENCY STOP beep 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
54. gulated and conditioned AC power One phase of the inverter is comprised of an Inverter Driver PCB 3G PCB high powered IGBT s a Protection Fuse and other monitoring and protecting components INVERTER MODULE PS 3 Figure 8 12 Location of Inverter Modules the 8 to 48KW ELI system i 722 qe M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 53 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Figure 8 13 Picture of the Inverter Module from a 8 to 48KW ELI system M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 54 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Table 8 6 LED Operation for the 3G PCB NORMAL ABNORMAL PCB FUNCTION LOCATION LED nm LED nM SOLUTION PCB LED Ham Description TN Description Illumination Illumination inverter Ensure cable connections are secure 3G Inverter Driver RST LED G1 Yes Inverter working No Inverter failure and correctly attached Module Replace the board H 9
55. ion 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 and incorporates 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED
56. l PCB to control the Rectifier Charger It also provides visual indication of the charging mode Figure 8 3 Location of 3B PCB in the PCB Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 44 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3 T 4 Sith gt Serre wie mm n 2 i Li ELS Figure 8 4 1 r 3B PCB Power Supply 617 a LE yeer re m m 4 nnm 1 LED B2 LED B6 LED B4 LED B7 LED B3 LED B1 Table 8 2 LED Operation for the 3B PCB NORMAL ABNORMAL PCB FUNCTION LOCATION LUTION SM SEANA PCB LED PED Description PED Description VOR Illuminated Illuminated Check fuse set behind PCB LED B1 holder and ensure cable B2 B3 All Yes PCB has power AlNo A LEDSofPCB nections are secure and extinguished B4 correctly attached Power Supply Module Replace the board LED B6 Yes The system is testing the batteries The system is boost charging the batteries M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 45 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO CO
57. llation manual carefully as it contains the necessary information required to install the ELI properly Thank you for choosing Always On M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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
58. n 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 4 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 and the inverter control switch lt gt 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
59. nded properly BATTERY TESTING performing test on the batteries Listed below are all the fault conditions that can be displayed 15 row HIGH DC SHUTDOWN DC Bus voltage out of operating range 2 row SHORT CIRCUIT a short circuit condition has occurred on the output FUSE OVERHEAT a fuse has blown or the system has shutdown due to overheating OVERLOAD SHUTDOWN system has exceeded the overload limit beyond the operating window EMERGENCY STOP user has activated the emergency stop feature INVERTER ABNORMAL inverter is not operating within specified parameters 39 row BYPASS ON SHUTDOWN inverter failure system operating in bypass mode The UP 7 or DOWN J key has no function in this menu The screen will go back to MENU 1 when ENTER 4 is pressed M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 20 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 5 4 Menu 3 Real Time Data Menu Figure 5 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 DA
60. ngerous 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 vii WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER TABLE OF CONTENTS 1 Introductio 1 1 1 DetinillOls quce tc Lande caedi 1 2 Theory OperallOhi 3 2 1 General Topology maswa a a die 3 2 2 Normal Operation Mode a 4 23 Backup Mod 4 2 4 Reserve Mode u bo oto td eR ais 2 2 5 Manual Bypass 2222222 2 2 01 1 0 10120000000000000000000000000000000 5 2 6 Ru mnsa Sa sapaska payaa s se 6 24 nVerler D reir 7 2 8 Static e h tai atta 8 2 9 Manual Bypass Switch sse 8 3 FrontPan el mcr rm TNT 9 4 NC 14 4 1 Switch On Procedure Authorized Trained Personnel Only 14 4 2 Shutdown Procedure ete ta Re i nn 15 4 3 From Inverter To Manual Bypass
61. nt the amount of current being supplied to the batteries M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 Figure 5 10 Other Data Menu Display when system in Back up UP 7 or DOWN key has no function in this menu The screen will return to MENU 3 when the ENTER 1 key is pressed 5 5 Menu 4 Historical Event Menu DATE TI ME EVENTS gt 2 1 2 01012 031 29 09 32 20 02 1 1 01 22 15 2 0031 10 15 47 Figure 5 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 be stored in one EEPROM This can be increased to 154 records with the addition of a second EEPROM The
62. on move the cursor gt by pressing the UP 7 key or the DOWN J 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 5 3 Menu 2 Status Warning Menu Figure 5 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 lt WARNING gt but this will be overridden by a fault message if more serious abnormal conditions occur and the title WARNING gt will then change to FAULT gt For example if a short circuit has occurred this screen will display as follows Figure 5 4 Warning Status Display with Fault Condition M4103 Borealis 8 48Kw Service Manual V3 1 2012 06
63. 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 fuse holders have not been opened power still present and fans will be turning If fuse holders open power is still present at the terminal strip and several terminals on the PCB s M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 16 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 switche
64. r 0 8 Factor 208 120 208 120 480 277 208 120 600 347 208 120 Input Output 208 120 480 277 Voltage Combinations 480 277 480 277 Available 3 phase 600 347 480 277 208 120 600 347 480 277 600 347 600 347 600 347 208 120V 208 120V 208 120V 50A 208 120V 70A 208 120V 90 208 120 208 120V 225A 250A AC Input 125A 175A Voltage Input 480 277V 20A 480 277 V 30A 480 277V 40A 80 277 480 277 V 80A 480 277 A 480 277 Service Amps 600 347V 15A 600 347V 30A 600 347V 30A 600 347V 50A 600 347V 60A 600 347V 80A 600 347V 90A 208 120V 208 120V 208 120V 208 120V 208 120V Output Voltage 22 33 4A 44 5A 66 7A 88 9A 208 120V 208 120V and Maximum 111 1A 133 3A Output C t 480 277V 9 7A 480 277V 480 277V 480 277V 480 277V SAM put n 14 5A 19 3A 28 9A 38 5A 480 277V 48 2A 480 277V 57 8 in Amperes at 10096 Load Y 600 347V 600 347V 600 347V 600 347V 600 347 38 5A 600 347V 46 2A 11 6 15 4 23 1 30 8 Standard Charger Size 10 10 10 15 20 25 30 amps DO System 348VDC nominal Voltage M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 75 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRA
65. re 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 interferen
66. ries at a faster rate and will improve the conditioning of the batteries Both of the above AUTO BOOST selections have six options for recharge rate 04 08 12 16 20 and 24 the numbers represent the number of hours the system will perform the boost charge for The option is selected by the number of battery bank the number of cells per battery bank and the type of batteries used within the battery bank The factory set value will be display or will flash if the option has been selected To select a different option use the UP 7 or the DOWN J key to select the time and press the ENTER J key to confirm M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 25 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Figure 5 16 Boost Charge Setting Menu Display Program Settings CHARGE CURRENT increases the amount of charge current the rectifier charge supplies the battery bank There are three possible options LO ME HI The factory will set the system at the optimal charge level for the battery bank provided To change the level of charge select the CHARGE CURRENT option then select the level of charge via the UP T and DOWN J keys Once the level of charge has
67. rovided 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 T or DOWN J key has no function this menu The screen will return to MENU when the ENTER 1 key is pressed Output Data Menu Figure 5 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 96 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 configured systems The UP 7 or DOWN J key has no function in this menu The screen will return to MENU when the ENTER 1 key is pressed Other Data Menu Figure 5 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 represe
68. ry 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 lt P 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER WARNING SIATUS ERE SMEH FER NRR NRR SMEH EATERY BATIOWSIOP INVERIER CONTROLS CD CONTROLS Figure 4 1 Status Panel Display Under Normal Operation Circles represent LED s that are on 4 2 Shutdown Procedure To completely shutdown the ELI please follow
69. se 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 or the 155 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 T key is pressed and move one record downward when the DOWN V key is pressed M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 23 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 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 5 6 Menu 5 Parameter Setting Menu Figure 5 12 Parameter Setting Menu Display MENU
70. tem initializes ok Once inverter attempts to assume load system beeps Inv Fail Shutdown LED turns on Fault LED turns on and Load LED flashes System remains in Static Bypass mode re attempting Inverter start up continually Figure 9 5 3T Board Fault A M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 66 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3T Board Fault B UPS system initializes ok Once inverter attempts to assume load system beeps Inv Fail Shutdown LED turns on and Fault LED turns on System remains in Static Bypass mode Figure 9 6 3T Board Fault B M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 67 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Inverter Module Fault UPS system initializes ok When DC Buss is established Fuse Temp fault LED turns on Inverter can not be turned on System operates in Static bypass mode only Figure 9 7 Inverter Module Fault M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 68 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERT
71. the following steps a Switch off the inverter The inverter can be switched off by simultaneously pressing the inverter off switch and the inverter control switch lt gt 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 wrap around 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 e Open the input breaker transformers will de energized M4103 Borealis 8 48 Service Manual V3 1 2012 06 22 15 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER f Now that all power has bee
72. tifi Yes Rectifier Enabled No 4 ectifier Enable outside of operating Check the input power 3C into 3CC and PCB parameters the Board 3CD board for Module Eu bi oar the option of 12 nsure cable connections are Bulbs All Yes has power All No PEB pate input secure and correctly attached Replace the board R S or T phase lost Ensure cable connections are Inverter Phase LED T1 T2 output on the 3T Control Module 12VDCA All Yes PCB has power All No secure and correctly attached indicating lost phase Replace the board T Ensure cable connections are Communication PCB LED R1 Interface 3R Interface Module 5VDCB Yes has power No communication failure attached nsure cable connections are Inverter Driver Inverter FED S1 bi i 3G RST Module Fuse Open Over Yes Inverter working No Inverter failure secure and correctly attached Temp Replace the board LED P1 Inverter output is Inverter operating Static RED Yes within normal No transfer from inverter Replace the board 3P Static Switch Switch Inverter S S parameters has failed Driver R S T Module LED P2 Reserve output is Inverter operating GRN Reserve Yes within normal No transfer from reserve Replace the board S S parameters has failed M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 71 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERM
73. tion Illumination Illumination 5 T phase lost TIT output LED on the Ensure cable connections are secure 3T Phase Control PCB Module T2 AllYes PCB has power All No front panel mimic 9 correctly attached diagram blinks indicating lost phase Replace the board M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 49 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 5 Communications Interface 3R PCB This is the local and remote Operator interface for the entire ELI system This controls the local front panel Operator interface by utilizing information from the Main Control PCB and translating and sending that to the front panel display PCB s Also receives the local Operator commands from front panel display PCB s and relays these to the Main Control PCB It also provides remote communication links via multiple protocols for Operator monitoring and control Figure 8 9 Location of 3R PCB in the PCB Module M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 50 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 0 pl h
74. tructions 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 NX Series 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 GE NERAL 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 ele
75. ully discharged and disconnect ELI from BBU prior to servicing TO PULL OUT A DRAWER REMOVE THESE TWO SCREWS gt BEFORE CABINET IS PLACED IN FINAL LOCATION REMOVE SIDE PANELS FROM BOTH SIDES OF CABINET TAKE OUT THESE TWO SCREWS FOR EACH DRAWER REPLACE SIDE PANELS Figure 13 2 Slide out BBU shelves M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 TI WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 14 Contact Information QA Warranty Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 758 Phone 250 491 9777 Ext 209 Fax 250 491 9775 Email qa alwayson com Website www alwayson com Software Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 758 Phone 250 491 9777 Ext 204 Fax 250 491 9775 Email webmaster alwayson com Website www alwayson com Additional Purchases or Upgrades Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 758 Phone 250 491 9777 Ext 451 Fax 250 491 9775 Email sales alwayson com Website www alwayson com M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 78 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE
76. uption 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 2 4 Reserve Mode A MANUAL BYPASS AUTOMATIC BYPASS TVSS FILTER RECTIFIER AC UTILITY TO LOAD INVERTER ISOLATION TRANSFORMER 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 2 5 Manual Bypass Mode MANUAL BYPASS gt AUTOMATIC BYPASS Z 252277 TVSS FILTER AC UTILITY A RECTIFIER INVERTER ISOLATION TRANSFORMER
77. ur modes of operation for an ELI system NORMAL MODE BACK UP BATTERY MODE RESERVE MODE and MAINTENANCE BYPASS MODE M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 2 2 Normal Operation Mode ee MANUAL BYPASS AUTOMATIC BYPASS uw INVERTER AC UTILITY RECTIFIER P CENE e TVSS FILTER TO LOAD TVSS Filter ISOLATION TRANSFORMER 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 2 3 Backup Mode MANUAL BYPASS a S AUTOMATIC BYPASS a TVSS FILTER RECTIFIER BATTERIES S Figure 2 3 Back up Mode Operation AC UTILITY TO LOAD TVSS Filter INVERTER ISOLATION TRANSFORMER 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 interr
78. 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 M4103 Borealis 8 48Kw Service Manual V3 1 2012 06 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Definitions Continued BBU Battery Backup Unit Power Factor Correction Emergency Power Off

M4103_Borealis_8-48Kw_Service_Manual V3.1 2012-06

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