Astrid UPS HALLEY/E Series, Product Manual

Page 1: ...UPS HALLEY E 20 80KVA PRODUCT MANUAL ...

Page 2: ...t wrong and unreasonable use Astrid Energy Enterprises holds itself responsible only for the equipment in its original configuration Any intervention altering the structure or the operating cycle of the equipment has to be carried out and authorized directly by Astrid Energy Enterprises Astrid Energy Enterprises cannot be held responsible of the consequences deriving from the use of non original s...

Page 3: ...2 2 INVERTER 10 2 2 1 Operation with non linear load 11 2 2 2 Overload management 12 2 2 3 Short circuit operation 13 2 2 4 IGBT bridge protection 14 2 3 BATTERY 15 2 4 STATIC SWITCH 15 2 4 1 Inverter Æ Emergency Line transfer 16 2 4 2 Emergency Line Æ Inverter transfer 16 2 5 MANUAL BY PASS 16 3 OPERATING MODES 17 3 1 NORMAL OPERATION 17 3 2 BATTERY OPERATION 18 3 3 BYPASS OPERATION 19 3 4 MANUAL...

Page 4: ... 6 External battery 36 5 2 6 1 Dimensions and weights 37 5 2 6 2 Connections 38 6 OPTIONS 39 6 1 INSULATION TRANSFORMERS 39 6 1 1 By pass insulation transformer 39 6 1 2 Rectifier insulation transformer 39 6 1 3 Voltage Adaptation Transformers 39 6 2 12 PULSE RECTIFIER 39 6 3 IP31 PROTECTION DEGREE 40 6 4 SPECIAL PAINT 40 6 5 FUSED SWITCH FOR THE BATTERY 40 6 5 1 Connections 41 6 5 2 Technical dat...

Page 5: ... FOR HALLEY E 20KVA 51 7 2 1 Level 1 51 7 2 2 Level 2 51 7 2 3 Level 3 51 7 2 4 Additional spares 51 7 3 SPARE PARTS FOR HALLEY E 30KVA 52 7 3 1 Level 1 52 7 3 2 Level 2 52 7 3 3 Level 3 52 7 3 4 Additional spares 52 7 4 SPARE PARTS FOR HALLEY E 40KVA 53 7 4 1 Level 1 53 7 4 2 Level 2 53 7 4 3 Level 3 53 7 4 4 Additional spares 53 7 5 SPARE PARTS FOR HALLEY E 60KVA 54 7 5 1 Level 1 54 7 5 2 Level ...

Page 6: ...pass for repair or maintenance works 22 Picture 19 Front panel 23 Picture 20 Menu structure 27 Picture 21 Handling of the UPS 31 Picture 22 Base plan 32 Picture 23 Dimensions and distances from the walls 33 Picture 24 Terminal board UPS 20 30kVA 34 Picture 25 Terminal board UPS 40 80kVA 34 Picture 26 Wiring 4 batteries for tray 35 Picture 27 Wiring 8 batteries for tray 36 Picture 28 Dimensions of ...

Page 7: ...er source CAUTION If primary powers isolators are installed in other area from UPS area the following warning label must be placed on them ISOLATE THE UPS BEFORE WORKING ON THIS CIRCUIT Dangerous voltage levels are present within the UPS It should be opened exclusively by qualified service personnel Warning after the UPS shut down a dangerous voltage will be present on the battery selector BCB The...

Page 8: ... relative humidity and ambient transport and storage conditions Using the UPS within the given limits guarantees its operation but may affect the service life of certain components particularly that of the battery and its autonomy The maximum storage time of the UPS is limited due to the need to recharge its integrated battery Unusual operating conditions may justify special design or protection m...

Page 9: ...larm work condition event log and battery state are displayed real time on the LCD front panel Picture 1 UPS block diagram With this configuration UPS guarantees high quality output needed by loads requiring stable and clean source of power The main features are Protection for black out in the limits of battery autonomy Complete filtering of main power noise High quality output power provided unde...

Page 10: ... Amplitude In I1 100 19 6 13 8 8 5 7 0 5 1 4 4 27 0 The inductor L3 reduces the current ripple generated by the inverter so that the battery life is improved During the battery discharge the inductor L3 works like a short circuit so that there s no voltage drop and the battery capacity can be completely used The rectifier is designed to recharge and keep charged Sealed Lead Acid Batteries although...

Page 11: ...g time Picture 3 Operation with ONE charging level 2 2 INVERTER The inverter converts the DC input voltage to AC voltage stabilized in frequency and RMS value The DC voltage is converted by the IGBT bridge that uses six switches controlled using PWM Pulse Width Modulation technology at high commutation frequency The PWM generation as well as the control of the operating variables is completely man...

Page 12: ... that the UPS can supply to a resistive load ex for a 100kVA UPS Pmax 80kW The table that follows the diagram shows an example of calculation for a 60kVA UPS Picture 5 Diagram of the power Example UPS 60kVA Pmax 48kW cos ϕ capacitive cos ϕ inductive 0 6 0 7 0 8 0 9 1 0 8 0 7 0 6 P Pmax 1 1 1 0 875 0 75 Max active power kW 32 37 3 42 6 48 48 48 42 36 Reactive power kVar 42 6 38 32 23 36 42 8 48 App...

Page 13: ... current to 200 for 5 cycles than reducing to 125 Any times output power grows above 100 the inverter keeps feeding the loads while the microprocessor activates the thermal image algorithm technical figure to calculate thermal image based on output current and duration of the overload in function of the time User loads are powered by inverter output up to the end of maximum allowed time then the s...

Page 14: ...e the increment of the energy When the limit is reached the inverter is switched off to avoid severe damages to the power components As soon as the bypass is available again the load is supplied by the bypass static switch After 30 minutes the inverter is switched on again and the load re supplied WARNING this operation causes the loss of the supply to the load 2 2 3 Short circuit operation As soo...

Page 15: ...ircuit The behaviour of the inverter in case of short circuit on the load has been described at 2 2 3 the output current is limited and the IGBT bridge current doesn t reach the protection threshold In case of short circuit in the inverter bridge the DC input current increases immediately and there s no possibility of limitation but stopping the PWM In this case the alarm A24 Current stop is activ...

Page 16: ...he battery is charged according to the DIN 41773 Standard every time it has been partially or completely discharged and it is kept floating even when it s charged to compensate any auto discharge UPS BATTERIES QUANTITY TYPE 20 kVA 5 minutes 32 12 Ah 30 kVA 5 minutes 64 7 Ah 20 kVA 10 minutes 64 7 Ah 30 kVA 10 minutes 32 24 Ah 20 kVA 15 minutes 32 18 Ah 2 4 STATIC SWITCH Static switch is based on p...

Page 17: ...ge shut down Emergency line within tolerance limits Forced commutation by BYPASS SWITCH test or service Emergency line within tolerance limits AND synchronized inverter 2 4 2 Emergency Line Æ Inverter transfer As soon as inverter is correctly working and synchronized UPS automatically switches to inverter in less than 1 msec If UPS switches back and forth more than 6 times in two minutes an alarm ...

Page 18: ...ating charge or boost charge depending on the type of battery The inverter converts the DC voltage into an AC sine wave stabilized in voltage and frequency and provides to supply the load through its static switch SSI Picture 13 Normal Operation Section Status Further explanation Rectifier Mains available and within the tolerance range RCB CLOSED Rectifier ON Battery available and within the toler...

Page 19: ...tion if not the inverter shuts down and the load is transferred to the bypass bypass operation If the bypass mains is not available or outside the tolerance range the complete system shuts down as soon as the lowest battery level is reached As soon as the power is restored the rectifier charges the battery and depending on the depth of the discharge the charging current is limited by means of the ...

Page 20: ...nd within the tolerance range may be outside the tolerance range RCB CLOSED Rectifier OFF ON Battery available and within the tolerance range BCB CLOSED Inverter ON Bypass Mains available and within the tolerance range BYPASS SWITCH BYPASS SBCB CLOSED Static Switch SSI OFF Static Switch SB ON OCB CLOSED MBCB OPEN Output Voltage available and within the tolerance range The automatic change over occ...

Page 21: ...tifier OFF ON depending on the reason of the transfer Battery NOT available or outside the tolerance range may be within the tolerance range BCB CLOSED Inverter OFF ON depending on the reason of the transfer Bypass Mains available and within the tolerance range BYPASS SWITCH NORMAL SBCB CLOSED Static Switch SSI OFF Static Switch SB ON OCB CLOSED MBCB OPEN Output Voltage available and within the to...

Page 22: ...ion Rectifier Mains available and within the tolerance range may be outside the tolerance range RCB CLOSED Rectifier ON OFF depending on the tests needed Battery available BCB OPEN CLOSED depending on the tests needed Inverter ON OFF depending on the tests needed Bypass Mains available and within the tolerance range BYPASS SWITCH NORMAL BYPASS depending on the tests needed SBCB OPEN CLOSED Static ...

Page 23: ...nd within the tolerance range may be outside the tolerance range RCB OPEN Rectifier OFF Battery available BCB OPEN Inverter OFF Bypass Mains available and within the tolerance range BYPASS SWITCH BYPASS SBCB OPEN Static Switch SSI OFF Static Switch SB OFF OCB OPEN MBCB CLOSED Output Voltage available supplied directly by the bypass mains ...

Page 24: ...ier input Otherwise off LED 2 Lit up green Emergency line present and phase sequence correct Otherwise off LED 3 Lit up green Rectifier feeding correctly Lit up red Rectifier output voltage out of tolerance LED 4 Lit up green Battery OK Green flashing Battery discharging or battery in test Orange flashing BCB open Lit up red Battery test aborted LED 5 Lit up green Inverter static switch closed Gre...

Page 25: ...A7 BCB OPEN Battery circuit breaker open A8 BATT DISCH The battery is discharging A9 BATT AUT END Battery autonomy calculated has expired A10 BATT FAULT Battery test failed or intervention of the safety timer during boost charge A11 BATT IN TEST Battery test in progress A12 PLL FAULT Problems with the digital synchronisation system A13 INV OUT TOL Inverter output voltage out of tolerance A14 OVERL...

Page 26: ...E The load is transferred to bypass for 30 minutes to allow a safe cooling of the inverter bridge A5 AC DC FAULT The inverter is switched off and the load is transferred to bypass A6 INPUT WR SEQ The rectifier is switched off The inverter is supplied by the battery provided the alarm A7 is not active battery breaker open A13 INV OUT TOL The load is transferred to bypass until the inverter output v...

Page 27: ...bypass input voltage BYPASS FREQUENCY Value in Hertz of the frequency of the bypass voltage INVERTER Description INVERTER VOLTAGE RMS value of the inverter output voltage measured upstream the inverter static switch INVERTER FREQUENCY Value in Hertz of the frequency of the inverter voltage AC DC Description AC DC VOLTAGE RMS value of the rectifier output voltage DC bus BATTERY Description BATTERY ...

Page 28: ...OM226142 rev C 27 4 3 MENU STRUCTURE Picture 20 Menu structure ...

Page 29: ... de rating for altitude 1000mt According EN62040 3 Ventilation FORCED Requested cooling air volume mt3 h 700 800 1200 1500 2100 Audible noise level according EN 50091 58dB 60dB Standard battery type lead acid N cells 192 Storage time of battery without recharge at 25 C 3 months Protection degree IP 20 EMC Compatibility According EN 50091 2 Paint RAL 5026 Met RAL 9006 Met Accessibility Front and to...

Page 30: ...into the mains 32 Battery Recharging Characteristic IU DIN 41773 Temperature Battery Voltage Compensation On Request Maximum Battery Recharging Current nominal load A 10 10 15 20 20 Rectifier Bridge Type Three Phase Full bridge rectifier Input protection Fast fuses Nominal Current Absorbed from Mains nominal load and Battery in floating A 34 50 66 100 133 Maximum Current Absorbed from Mains nomina...

Page 31: ...hort Circuit Characteristic Elect short circuit protection current limited at 2 times nominal current Selectivity Within cycle fus gG 20 In Output Waveform Sinusoidal Output Harmonic Distortion Linear Load Non Linear Load 2 5 Crest Factor 3 1 Max DC current absorbed by inverter during battery discharge 320Vdc and nom load A 54 5 81 8 107 160 213 5 1 4 STATIC BY PASS Automatic Static By Pass Electr...

Page 32: ...position as indicated on the packing and conserved in a dry and sheltered room in its box so that it is protected from dust 5 2 2 Handling of the UPS Before positioning the UPS in order to avoid risks of turnover it s recommended to move the system on the wood pallet on which the UPS is fixed Before the positioning in the final location remove the UPS from the pallet The UPS can be lifted and hand...

Page 33: ...l ambient will have to be according to EN 50091 1 annex N The picture 22 and the following tables show the base plan of the UPS with the related dimensions and the weight of the unit with internal batteries 5 2 3 1 Base plan static load and weights Picture 22 Base plan UPS kVA 20 30 40 60 80 L1 mm 650 650 650 650 650 P1 mm 820 820 820 820 820 L2 mm 25 25 25 25 25 UPS kVA 20 30 40 60 80 Weight w o ...

Page 34: ...23 Dimensions and distances from the walls UPS kVA 20 30 40 60 80 L mm 690 P mm 865 H mm 1345 X min mm 50 Y min mm 500 ADD CABINET AS028 AS029 L1 mm 620 815 P1 mm 645 820 H1 mm 1150 1340 The additional cabinets AS028 and AS029 are cabinets for external battery ...

Page 35: ...the front door WARNING The connection to the mains must be carried out with protection fuses or circuit breakers between the mains and the UPS The use of residual current devices in the line supplying the UPS is unadvisable The leakage current due to the RFI filters is rather high and it can cause spurious tripping of the protection device According to the EN62040 1 standard in order to take into ...

Page 36: ...o be at least 0 005 NI m3 per hour where N is the number of the elements inside the battery and I is maximum current of the rectifier The batteries can be internal or external however it is recommended to install them when the UPS is capable of charging them Please remember that if the battery is not charged for periods over 2 3 months they can be subject to irreparable damage In order to avoid an...

Page 37: ...used to increase the UPS autonomy time during mains failure It s always provided for UPS having rating 30KVA IMPORTANT With an external battery the internal battery isn t necessary The external battery consisting of 32 battery blocks maximum with 6 cells each for 192 cells total can be installed in three different cabinets AS028 for 38Ah battery blocks AS029 for 65Ah battery blocks AS182 for 130Ah...

Page 38: ...et standard length 5m The standard colour for the external battery cabinet is RAL 5026 the protection level is IP20 5 2 6 1 Dimensions and weights AS028 AS029 AS182 Picture 28 Dimensions of the external battery cabinets AS028 AS029 AS182 Picture 29 Base plan of the external battery cabinets ...

Page 39: ...0x180x190 410x220x280 Max Nominal Capacity per block 38 Ah 65 Ah 130 Ah Weight of single block 14 6 Kg 24 Kg 45 Kg 5 2 6 2 Connections The following picture shows the electrical connection between the UPS and the external battery cabinet Picture 30 Battery cabinets connections The connection cables are two power cables with section of 50mm2 and with length ranging from 2 to 50m Longer cables are s...

Page 40: ... from the mains THD to a value lower than 12 This ensures that the rectifier does not distort the supply mains with regard to the other loads it also avoids the overheating of the cables due to the harmonics circulation This technology uses two 6 pulse rectifier bridges which operates with an input voltage having a phase displacement of 30 the two DC outputs are connected in parallel through two s...

Page 41: ...tional roof is added to guarantee the protection against the falling of drops of water and additional grids with smaller holes are installed behind the existing openings 6 4 SPECIAL PAINT Different colours are available on request and with an additional cost The special paint can be requested according to the RAL colours standard 6 5 FUSED SWITCH FOR THE BATTERY The fused switch for the battery is...

Page 42: ...ith fuses is connected between the UPS and the external battery cabinet as illustrated below Picture 32 Connection of the battery fused switch 6 5 2 Technical data Colour RAL 7032 Protection degree IP20 UPS kVA 20 30 40 60 80 L mm 400 500 P mm 200 200 H mm 400 700 L1 mm 360 460 H1 mm 360 660 UPS kVA 20 30 40 60 80 Switch type 2 pole fused switch 3 poles switch fuses Fuses size A 80 Gg 80 Gg 125 Gg...

Page 43: ...additional monitoring card provides to activate the alarm A20 on the LCD display in case of any fans failure 6 8 DIESEL GENERATOR INTERFACE The diesel generator interface provides to limit the rectifier output voltage in order not to recharge the battery during the Gen Set operation In this way the rectifier needs a lower current to feed the DC loads inverter and a considerable amount of energy is...

Page 44: ... 34 Charging voltage vs temperature The temperature sensor is housed inside a plastic tube and already provided with a three pole cable that must be connected to an interface card installed next to the UPS terminal board section The temperature sensor can be installed at a maximum distance of 15 meters from the UPS 6 10 BOOST CHARGE This type of charge according to DIN41773 is used with vented lea...

Page 45: ...der to avoid the over heating or excessive consumption of the electrolyte the microprocessor is equipped with a safety timer that provides to stop the boost charge in case it exceeds 12 hours An alarm indication on the display warns the user that something is wrong with the batteries 6 11 PARALLEL REDUNDANT CONFIGURATION Picture 36 Parallel redundant block diagram The parallel system consists of n...

Page 46: ...ating conditions with no alarms all relays are energized Relay Alarms Status Status M1 Led Pins Status Name Status RL1 Not available 17 18 D7 16 17 RL2 Not available 14 15 D8 13 14 RL3 Status Inverter feeds the load Energized 11 12 Closed D9 On 10 11 Open RL4 Alarm Bypass feeds the load Not energized 8 9 Open D10 Off 7 8 Closed RL5 Alarm Battery low Not energized 5 6 Open D11 Off 4 5 Closed RL6 Al...

Page 47: ...el dimensions 320 x 210 x 60 mm W x D x H Power requirements 220 240Vac 50 60Hz The remote panel includes Remote panel with standard supply cable L 1m RS485 connection cable standard length 8m 6 15 TELEPHONE CONNECTION KIT This package provides hardware and software required to connect the UPS to a remote PC through a telephone line The remote PC can dial the UPS through a modem and a dedicated li...

Page 48: ...down through the PC or the Server The program can work in background while other programs are in use and in case of an alarm the UPS control screen is visualized pop up function The program allows to translate into another language all the labels present in the various formats Italian English and German version are available as standard Picture 40 Voyager E screen The VOYAGER E package includes So...

Page 49: ... next paragraph 6 18 ADDITIONAL LICENSES FOR UPS MANAGEMENT SOFTWARE The additional licenses allow the installation of the RCCMD Remote Console CoMmanD service in the servers where the shutdown is required This service enable the servers to listen to the RCCMD commands sent through the network by the UPSMAN that is the PC where the management software is installed thus commanding a shutdown when r...

Page 50: ...OM226142 rev C 49 6 21 SELECTION OF THE UPS USER INTERFACE ...

Page 51: ...OM226142 rev C 50 7 SPARE PARTS LIST 7 1 INTRODUCTION The spare parts for PLANET E are divided into three different levels Level 1 fuses Level 2 electronic cards Level 3 semiconductors fans capacitors ...

Page 52: ...FIRING FIR 91 1 1 PB114 RECTIFIER CONTROL LOGIC POWER SUPPLY PRCH 1 1 PB115 RECTIFIER CONTROL LOGIC LOOP 1 1 PB121 122 SYSTEM CONTROL PANEL E SCP E 1 1 7 2 3 Level 3 ASTRID CODE DESCRIPTION TYPE VALUE QUANTITY Inst Rec SCRD56A12V RECTIFIER BRIDGE POWER MODULE 56A 1200V 3 2 IGD75A12V IGBT INVERTER POWER BRIDGE 75A 1200V 3 2 SCRD56A12V INVERTER STAT SWITCH THYRISTORS 56A 1200V 3 1 SCRD56A12V BYPASS ...

Page 53: ...RING FIR 91 1 1 PB114 RECTIFIER CONTROL LOGIC POWER SUPPLY PRCH 1 1 PB115 RECTIFIER CONTROL LOGIC LOOP 1 1 PB121 122 SYSTEM CONTROL PANEL E SCP E 1 1 7 3 3 Level 3 ASTRID CODE DESCRIPTION TYPE VALUE QUANTITY Inst Rec SCRD91A12V RECTIFIER BRIDGE POWER MODULE 91A 1200V 3 2 IGD100A12V IGBT INVERTER POWER BRIDGE 100A 1200V 3 2 SCRD56A12V INVERTER STAT SWITCH THYRISTORS 56A 1200V 3 1 SCRD56A12V BYPASS ...

Page 54: ... VOLT REF 3F 1 1 PB116 RECTIFIER CONTROL LOGIC POWER SUPPLY SYNC 12 1 1 PB117 RECTIFIER CONTROL LOGIC RCLS 1 1 1 PB121 122 SYSTEM CONTROL PANEL E SCP E 1 1 7 4 3 Level 3 ASTRID CODE DESCRIPTION TYPE VALUE QUANTITY Inst Rec SCRD132A12V RECTIFIER BRIDGE POWER MODULE 132A 1200V 3 2 IGD200A12V IGBT INVERTER POWER BRIDGE 200A 1200V 3 2 SCRD56A12V INVERTER STAT SWITCH THYRISTORS 56A 1200V 3 1 SCRD91A12V...

Page 55: ...OLT REF 3F 1 1 PB116 RECTIFIER CONTROL LOGIC POWER SUPPLY SYNC 12 1 1 PB117 RECTIFIER CONTROL LOGIC RCLS 1 1 1 PB121 122 SYSTEM CONTROL PANEL E SCP E 1 1 7 5 3 Level 3 ASTRID CODE DESCRIPTION TYPE VALUE QUANTITY Inst Rec SCRD132A12V RECTIFIER BRIDGE POWER MODULE 132A 1200V 3 2 IGD300A12V IGBT INVERTER POWER BRIDGE 300A 1200V 3 2 SCRD91A12V INVERTER STAT SWITCH THYRISTORS 91A 1200V 3 1 SCRD91A12V B...

Page 56: ...REF 3F 1 1 PB116 RECTIFIER CONTROL LOGIC POWER SUPPLY SYNC 12 1 1 PB117 RECTIFIER CONTROL LOGIC RCLS 1 1 1 PB121 122 SYSTEM CONTROL PANEL E SCP E 1 1 7 6 3 Level 3 ASTRID CODE DESCRIPTION TYPE VALUE QUANTITY Inst Rec SCRD132A12V RECTIFIER BRIDGE POWER MODULE 132A 1200V 3 2 IGD400A12V01 IGBT INVERTER POWER BRIDGE 400A 1200V 3 2 SCRD91A12V INVERTER STAT SWITCH THYRISTORS 91A 1200V 3 1 SCRD132A12V BY...