Borri B9000FXS 100kVA, Product Manual

Page 1: ...ncorrect wrong and unreasonable use Borri 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 Borri Borri cannot be held responsible of the consequences deriving from the use of non original spare parts Borri reserves its right to carry out tech...

Page 2: ... BYPASS 14 2 OPERATING MODES 15 2 1 NORMAL OPERATION 15 2 2 BATTERY OPERATION 16 2 3 BYPASS OPERATION 17 2 4 MANUAL BYPASS 18 3 FRONT PANEL 19 3 1 FUNCTION BUTTONS 19 3 2 FUNCTION OF MIMIC PANEL LED S 19 3 3 ALARMS AND OPERATING STATUS 21 3 4 MEASUREMENTS ON THE DISPLAY 22 4 GENERAL TECHNICAL INFORMATION 23 4 1 TECHNICAL DATA 23 4 2 INSTRUCTIONS FOR INSTALLATION 23 4 2 1 Receipt of the UPS 23 4 2 ...

Page 3: ... SET VIA SOFTWARE 41 5 1 1 Diesel generator 41 5 1 2 Off line 41 5 1 3 Two level charge Boost Charge 42 5 1 4 Programmable rectifier soft start Walk in 43 5 1 5 Sequential rectifier start for parallel systems Hold off 43 5 1 6 Frequency converter 43 5 1 7 DCM function 43 5 2 OPTIONS PROVIDED ON REQUEST 43 5 2 1 Thermal compensation of battery charge 44 5 2 2 Bypass insulation transformer 44 5 2 3 ...

Page 4: ...12 Normal operation 15 Picture 13 Battery operation 16 Picture 14 Bypass operation manual changeover 17 Picture 15 Bypass operation automatic changeover 17 Picture 16 Manual Bypass for functional tests 18 Picture 17 Manual Bypass for repair or maintenance works 18 Picture 18 UPS front panel 19 Picture 19 UPS mimic panel 19 Picture 20 Handling of UPS B9000FXS 24 Picture 21 Base plan 25 Picture 22 O...

Page 5: ...rom the top 50 Picture 38 UPS dimensions with additional cabinet for cables inlet from the top 50 Picture 39 Base plan of UPS with additional cabinet for cables inlet from the top 51 Picture 40 Example of UPS units in Sync Load configuration single configuration 52 Picture 41 Example of UPS units in Sync Load configuration single configuration 53 Picture 42 Example of UPS units in Sync Load config...

Page 6: ...ement alarm work condition event log and battery state are indicated real time on the display 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 mains power noise High quality output power provided unde...

Page 7: ...ital control of the IGBT bridge allows to minimize the harmonics re injected into the mains and reduces the harmonic distortion of the current to a very low value even with low loads The trend of the power absorbed by the mains is almost sinusoidal with a power factor higher than 0 99 thanks to the PFC Power Factor Correction technology The current transducers TA1 TA2 TA3 provide the feedback for ...

Page 8: ... 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 managed by the microprocessor The current transducer CT provides f...

Page 9: ...s department to verify whether a slight power de rating is necessary or not 1 2 1 Operation with non linear load A non linear load is characterized by a high peak current versus its RMS value that in normal condition would introduce a distortion on the output voltage waveform The inverter is provided with an instantaneous voltage correction facility completely managed by the microprocessor that pr...

Page 10: ...output current and duration of the overload User loads are powered by inverter output up to the end of maximum allowed time then the static switch transfers the load to the emergency line without interruption of output power Picture 6 Thermal image characteristic Picture 7 Overload with bypass available 1 BYPASS AVAILABLE As soon as an overload is detected the algorithm starts to calculate the inc...

Page 11: ...n again and the load is transferred again to the primary supply WARNING this operation causes the loss of the supply to the load 1 2 3 Short circuit operation As soon as an output short circuit is detected alarm A25 the load is transferred immediately to the emergency line that provides to eliminate the fault thanks to its higher short circuit current In case the bypass is not available the invert...

Page 12: ...rter 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 does not reach the protection threshold In case of short circuit in the inverter bridge the DC input current increases immediately and there is no possibility of limitation but stopping the PWM In this case the alarm A12 Max Current Stop is activated and must be reset man...

Page 13: ...me it has been partially or completely discharged It is kept floating even when it is charged to compensate any auto discharge 1 4 STATIC SWITCH Static switch is composed of thyristors rated to work continuously at 150 of nominal output power The components connected to the bypass line are protected by fuses Picture 11 Static switch and manual bypass Thanks to the transfer logic integrated in the ...

Page 14: ...tolerance limits and SYNCHRONIZED inverter 1 4 2 Emergency Line Inverter Transfer As soon as inverter is correctly working and synchronized UPS automatically switches the load to inverter in less than 1 msec If UPS switches back and forth more than 6 times in two minutes an alarm will be generated to inform the user and the load will be locked to emergency line A manual reset is necessary to switc...

Page 15: ...he rectifier supplies the inverter and compensates mains voltage fluctuations as well as load variation maintaining the DC voltage constant At the same time it provides to keep the battery in stand by floating charge or boost charge depending on the type of battery The inverter converts the DC voltage into an AC sine wave with stabilized voltage and frequency and also supplies the load via its sta...

Page 16: ...uts down as soon as the lowest battery level is reached black out As soon as the power is restored the rectifier charges the battery In the standard configuration the loads are supplied again via static switch SSB when mains is available again The inverter is restarted when the battery has partially restored its capacity The system restart from the black out condition can be customized based on th...

Page 17: ...ypass In the event of a bypass failure the load is transferred back to inverter without interruption Picture 14 Bypass operation manual changeover The automatic change over occurs for the reasons explained in paragraph 2 4 1 basically when the power supply to the load within the specified tolerance cannot be assured by the inverter Picture 15 Bypass operation automatic changeover ...

Page 18: ...e followed carefully in order to avoid damages to the UPS During the functional check of the UPS all the breakers can be closed except for the output breaker OCB and the full functionality can be tested Picture 16 Manual Bypass for functional tests During the manual bypass operation for repair or maintenance the UPS is completely switched off and the load is supplied directly by the bypass mains P...

Page 19: ...of the UPS Picture 18 UPS front panel 3 1 FUNCTION BUTTONS The front panel of the UPS is provided with 5 buttons whose functions are indicated in the following table Button Assigned functions Scrolls up the menus Increases the values by one unit Selects a value Scrolls down the menus Increases the values by one unit Selects a value Selects a menu Confirms changes Silences the buzzer activated due ...

Page 20: ...T ORANGE Circuit breaker BCB open RED Battery fault following a battery test OFF Battery not available LED 5 GREEN Inverter voltage within tolerance and static switch closed GREEN Inverter overload or short circuit OFF Inverter off or voltage out of tolerance LED 6 ORANGE Re transfer blocked ORANGE Static bypass switch closed OFF Static bypass switch open LED 7 GREEN output circuit breaker OCB clo...

Page 21: ...T A39 INV ERROR LOOP A12 STOP TIMEOUT SC A40 SSI FAULT A13 INV OUT OF TOL A41 RECT ERROR LOOP A14 BYPASS WR SEQ A42 INP FUSES BLOWN A15 BYPASS FAULT A43 CURR ERROR LOOP A16 BYPASS LOAD A44 DESAT IGBT INV A17 RETRANSFER BLOCK A45 HIGH TEMP SSW A18 MBCB CLOSED A46 PAR LOST REDUND A19 OCB OPEN A47 SEND PARAM ERROR A20 OVERLOAD A48 RCV PARAM ERROR A21 THERMAL IMAGE A49 TEST MODE ERROR A22 BYPASS SWITC...

Page 22: ...rrent 3 1 A Frequency 0 1 Hz Input power 1 kVA OUTPUT Voltage 1 2 1 V Current 3 1 A Frequency 0 1 Hz Active power 1 kW Apparent power 1 kVA Load percentage 1 BYPASS Voltage 1 2 1 V Frequency 0 1 Hz INVERTER Voltage 1 2 1 V Frequency 0 1 Hz AC DC Rectifier output voltage 1 V BATTERY Voltage and current 1 V 1 A Nominal capacity 1 Ah Residual autonomy 1 min 1 1 The voltage measures are always referre...

Page 23: ...product need to be returned to the manufacturer please use the original package Danger to persons due to transport damages Mechanical damage to the electrical components constitutes a serious danger to persons and property In case of doubt regarding the non integrity of the package or of the product contained therein contact the manufacturer before carrying out the installation and or the start up...

Page 24: ...ice has a heavy weight Avoid turnover during the transport of the UPS Cabinets must always be handled in upright position During loading and unloading operations always respect the indications regarding the device barycentre marked on the package To handle the UPS remove the lower front and rear panel and insert the forks of a fork lift Picture 20 Handling of UPS B9000FXS ...

Page 25: ...or dripping explosive dust and gas mixture extreme temperature variations bad ventilation conductive or radiant heat from other sources fungus insects vermin 4 4 1 Base plan static load and weights Picture 21 Base plan UPS kVA 60 80 100 125 160 L1 mm 815 P1 mm 825 L2 mm 70 The supporting base of the UPS must be designed to carry the UPS weight and to ensure its steady and safe support Its carrying...

Page 26: ...OMD10078 rev F 26 4 4 2 Overall dimensions Picture 22 Overall dimensions of UPS B9000FXS UPS kVA 60 80 100 125 160 L mm 815 P mm 825 H mm 1670 ...

Page 27: ...inimum distances from the walls for all of the UPS sizes the same installation conditions apply as indicated in the table below Picture 23 Minimum distances from the walls A mm B mm C mm D mm 1000 700 200 50 The table below shows the air volume required for an optimal ventilation and cooling of the UPS A mm B mm C mm D mm 1000 700 200 300 UPS kVA 60 80 100 125 160 Air volume m3 h 1600 1800 2100 23...

Page 28: ...ion of biological conditions EN 60721 3 3 Environmental parameter Class 3B1 3B2 3B3 a Flora NO Presence of mildew fungus etc Presence of mildew fungus etc b Fauna NO Presence of rodents and other animals that are harmful to products excluding termites Presence of rodents and other animals that are harmful to products including termites Classification of mechanically active substances EN 60721 3 3 ...

Page 29: ... atmosphere is permanently monitored X Places located in rural and urban regions where industrial activities are few and where traffic is moderate X Places located in urban regions with industrial activities and or considerable traffic X Places in proximity to industrial sources with chemical emissions X Places located in industrial installations Emissions of highly concentrated chemical pollutant...

Page 30: ... manufacturer For this reason the following recommendations are only an indication as the UPS manufacturer is not responsible for the electrical installation In any case we recommend to carry out the installation and the electrical connections of the input and output in compliance with the local standards Cables must be selected bearing in mind technical financial and safety aspects The selection ...

Page 31: ...ut with protection fuses between the mains and the UPS The use of differential protection devices in the line supplying the UPS is unadvisable The leakage current to ground due to the RFI filters is rather high and it can cause spurious tripping of the protection device According to IEC EN62040 1 standard in order to take into account the UPS leakage current residual current devices having adjusta...

Page 32: ...e a mains failure The use of a device installed inside the UPS allows a higher flexibility of use as only the bypass line is cut leaving the rectifier battery charger in operation The use of an external device forces the user to separate the UPS supply lines rectifier and bypass if the flexibility and availability of the UPS are supposed to be kept unaltered The following table shows the main elec...

Page 33: ...OMD10078 rev F 33 4 7 TERMINAL BOARDS UPS B9000FXS is provided with terminal boards for the power connections and auxiliary contacts Picture 24 Position of power terminals of B9000FXS ...

Page 34: ... the loads Injury hazard due to electric shock Very high voltages are present at the ends of the cables coming from the battery isolate the battery via DC circuit breakers before connecting it to the UPS connect the ground cable to the relevant bar before carrying out any other connection inside the device Risk of damages to the device due to insufficient insulation The cables must be protected fr...

Page 35: ...S is already provided with the FCI card Free Contact Interface which allows to place some external controls remotely such as External manual bypass Diesel generator Auxiliary battery contact Remote emergency power off button EPO The auxiliary cables are connected using a special terminal board placed aligned with the power terminal boards The section of the terminals used is 6 mm2 Picture 25 Posit...

Page 36: ...s when the contact is closed if diesel mode is enable the microprocessor will acquire the status of the contact and the rectifier will reduce the voltage to the value set 4 9 3 Auxiliary battery contact Aux battery contact on terminals BAC1 BAC2 This auxiliary contact is necessary to indicate the position of the isolator open closed and the fuse status 4 9 4 Remote emergency power off Aux EPO cont...

Page 37: ...nnection to the proprietary programming and control software MODBUS OPTIONAL is used for the transmission of data to the outside via MODBUS protocol RS485 Parallel OPTIONAL is used for communication between paralleled UPS units SNMP OPTIONAL is used for the external transmission of data via LAN NORMAL BYPASS selector NORMAL SERVICE selector Picture 27 Interfaces of UPS B9000FXS ...

Page 38: ...ough the battery can operate up to 40 C there will be a significant reduction of the battery life To avoid the formation of any kind of potentially explosive hydrogen and oxygen mixture suitable ventilation must be provided where the battery is installed see EN62040 1 2 For the materials installed in France we have to apply the rules according to NFC 15 100 article 554 2 the volume of the renewed ...

Page 39: ...OMD10078 rev F 39 4 11 1 1 Dimensions and weights Picture 28 Dimensions of the external battery cabinet Picture 29 Base plan of the external battery cabinet ...

Page 40: ...block 45 kg 45 kg 4 11 1 2 Connections The following picture shows the electrical connections between the UPS and the external battery cabinets Picture 30 Battery cabinets connections The connection cables are two power cables whose section is shown in the following table and length ranging from 2 to 50m Longer cables are subject to excessive voltage drop so their section must be increased accordi...

Page 41: ...ut voltage in order not to recharge the batteries 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 saved therefore the rating of the generator power can be lower A contact indicating the Gen Set operation must be connected to two terminals XD1 XD2 already provided on the UPS terminal board Picture 31 B...

Page 42: ...rging current exceeds a certain threshold generally 0 08C10 the rectifier switches to BOOST charge 2 4 V cell for lead acid batteries 1 55 V cell for Ni Cd batteries and starts a charging cycle with the first part at constant current and increasing voltage When the voltage reaches the boost charge level the current begins to decrease until it reaches the second threshold generally 0 03C10 and the ...

Page 43: ...emporally distribute the load supplied by the generator 5 1 6 Frequency converter The values of the Frequency Converter function can be enabled and set via the Test Software The frequency converter function allows to have a 60 Hz frequency on the UPS output whereas the input frequency is 50 Hz or vice versa When enabling this function the bypass will be automatically disabled as it is no longer po...

Page 44: ...d installed in the UPS terminal board section The temperature sensor can be installed at a maximum distance of 15 meters from the UPS 5 2 2 Bypass insulation transformer It is used when the input line is without neutral or the galvanic isolation between the mains and the loads is required During normal operation the inverter transformer provides for this task while during the bypass condition the ...

Page 45: ...pen D2 Off 4 5 Closed RL3 Alarm Battery low Not energized 8 9 Open D3 Off 7 8 Closed RL4 Alarm Inverter out of tolerance Not energized 11 12 Open D4 Off 10 11 Closed RL5 Alarm Bypass feeds load Not energized 14 15 Open D5 Off 13 14 Closed RL6 Status Booster OK Energized 17 18 Closed D6 On 16 17 Open RL7 Status Inverter feeds the load Energized 20 21 Closed D7 On 19 20 Open RL8 Status Bypass OK Ene...

Page 46: ...signal that can be silenced by the user The regular operating conditions of the UPS are indicated by the lighting of LED UPS OK 5 2 8 Parallel kit The parallel kit allows to prearrange a UPS configured as a single unit for its connection and configuration in a parallel redundant system Thanks to the DSP microprocessor and to the CAN BUS communication system configuring the UPS from single to paral...

Page 47: ...er any load condition The load is supplied by the inverters in parallel also in the event of an instantaneous overload n x 200 of the nominal load of the single unit In the event that a failure occurs to one of the units the load is switched to the Emergency Line Bypass like in the case of a UPS in single configuration Picture 34 Example of UPS units connected in parallel ...

Page 48: ... the battery is installed in a dedicated room therefore it is necessary to use an isolation device between the UPS and the battery It is installed in a separate box and equipped with an auxiliary contact to indicate the position of the isolator open closed and the fuse status 5 2 11 Connections The battery isolator is connected between the UPS and the external battery as indicated in the following...

Page 49: ...echnical data of battery isolator Colour RAL 7035 Protection degree IP20 UPS kVA 60 80 100 125 160 L mm 500 P mm 250 H mm 700 L1 mm 460 H1 mm 660 UPS kVA 60 80 100 125 160 Isolator type 4 pole Isolator Fuses Fuse size A 200 gG 200 Gg 200 Gg 250 Gg 315 Gg ...

Page 50: ...top This option allows to obtain the cables inlet from the top with an additional cabinet Picture 37 UPS dimensions with additional cabinet for cables inlet from the top Picture 38 UPS dimensions with additional cabinet for cables inlet from the top ...

Page 51: ...OMD10078 rev F 51 Picture 39 Base plan of UPS with additional cabinet for cables inlet from the top 5 2 14 Special painting All the RAL colours can be requested with an additional cost ...

Page 52: ...ER CONNECT THEIR OUTPUTS TOGETHER If one or more UPS units have the emergency line available which must be the same for all the systems the UPS configured with the lowest position will synchronize with the emergency line All the other UPS units will synchronize with such UPS so they will be synchronized in their turn with the emergency line whether it is present on the UPS or not The emergency lin...

Page 53: ...S in parallel configuration Picture 43 explains the interconnection of two systems A and B in the sync load operation The external SYNC BOX is connected by CANBUS cable to the system A and system B After the sync load function is enabled in both systems the SYNC BOX will provide to keep the systems output synchronised on various operating conditions Picture 42 Example of UPS units in Sync Load con...

Page 54: ...n Sync Load configuration parallel configuration 5 2 17 Back feed protection from power return to mains This option prevents the risks deriving from power return to mains and from the faults caused by the failure of the SCR s of the static bypass switch ...