Borri E2001 COMPACT, Operating And Maintenance Manual

Page 1: ...OPERATING AND MAINTENANCE MANUAL E2001 COMPACT E3001 COMPACT ...

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Page 3: ...PS OPERATING AND MAINTENANCE MANUAL Indice di sessione Codice 1 UPS GENERAL DESCRIPTION AND INSTALLATION OMX76006 2 FRONT PANEL AC UPS GD 128X64 OMX76007 3 START UP SHUT DOWN AND MANUAL BYPASS OMX76008 AVVERTENZA This is a product for commercial and industrial application in the second environment installation restrictions or additional measures may be needed to prevent disturbances ...

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Page 5: ...acking 5 1 1 3 Lead battery 5 1 2 SAFETY RULES 5 1 2 1 Safety of persons 5 1 2 2 Product safety 5 1 2 3 Special precautions 6 2 UPS GENERAL DESCRIPTION 7 2 1 TYPOLOGY 7 2 2 SYSTEM DESCRIPTION 8 2 2 1 Rectifier 8 2 2 2 12 pulses rectifier 8 2 2 3 Inverter 9 2 2 4 Battery charger 9 2 2 5 Static bypass 9 2 2 6 Manual bypass 9 2 2 7 Front panel 9 2 3 OPERATING STATUS 10 2 3 1 Normal operation 10 2 3 2...

Page 6: ...UPS general description installation 2 OMX76013 REV A 3 2 HANDLING OF THE UPS 12 3 3 POSITIONING AND INSTALLATION 13 3 4 ELECTRICAL CONNECTION 13 3 5 BATTERY INSTALLATION 13 ...

Page 7: ...f pictures Picture 1 Block diagram 7 Picture 2 12 pulses rectifier with galvanic isolation 8 Picture 3 Normal operation 10 Picture 4 Load supplied by bypass 10 Picture 5 Rectifier failure or mains failure 11 Picture 6 Manual bypass 11 Picture 7 Handling of UPS 12 ...

Page 8: ...UPS general description installation 4 OMX76013 REV A ...

Page 9: ...nected to a battery 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 UPS must be properly earthed The battery supplied with the UPS contains small amounts of toxic materials To avoid accidents the directives listed below must be obser...

Page 10: ...ing 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 measures harmful smoke dust abrasive dust humidity vapor salt air b...

Page 11: ... of EN62040 1 the installer will have to identify the line or the plugs supplied by the UPS making the User aware of this fact This configuration guarantees the best service to the User as it supplies clean continuously regulated power and guarantees the voltage and frequency will be stabilised at nominal value independently from mains status Thanks to the double conversion it makes the load compl...

Page 12: ...n This technology uses two 6 pulse rectifier bridges which operates with an input voltage having a phase displacement of 30 This configuration allows the system to cancel the typical harmonics of the 6 pulses rectifier namely the 5th and 7th As a consequence only the higher order harmonics remain the 11th 13th and the multiples This system is highly recommended for high power equipment where the c...

Page 13: ... or completely discharged and it is kept floating even when it s charged to compensate for any autodischarge 2 2 5Static bypass It s designed to transfer the load between INVERTER and MAINS and vice versa without break and uses SCR s as power commutation elements 2 2 6Manual bypass It s used to by pass the UPS supplying the load directly to the mains in case of maintenance or serious failure WARNI...

Page 14: ...Normal operation The inverter is supplied by the rectifier the load through the static switch is supplied directly by the inverter output Picture 3 Normal operation 2 3 2Load supplied by bypass due to inverter fault The load is transferred to bypass through the static switch the transfer is carried out without interruption Picture 4 Load supplied by bypass ...

Page 15: ...e required autonomy time the load through the static switch is supplied directly by the inverter output Picture 5 Rectifier failure or mains failure 2 3 4Manual bypass The load is supplied by the mains through the manual bypass the operator can work in safety on the UPS to carry out maintenance or repairing operations Picture 6 Manual bypass ...

Page 16: ...ed carefully in vertical position as indicated on the packing and conserved in a dry and sheltered room in its box so that it is protected from dust 3 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...

Page 17: ...ove the protection extracting the fixing bolts WARNING The connection to the mains must be carried out with protection fuses 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 t...

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Page 19: ...PLAY 8 4 LCD 9 4 1 MEASUREMENTS DISPLAY 10 4 2 USER COMMANDS MENU 12 4 2 1 Reset UPS command 13 4 2 2 Battery test commands 14 4 3 BASIC DIAGNOSTICS 15 4 3 1 Device status 15 4 3 2 Log 16 4 3 3 List of alarms and statuses of the rectifier 17 4 4 SETTINGS AND ADVANCED OPERATIONS 18 4 4 1 Input Settings 19 4 4 2 Inverter Settings 19 4 4 3 Output Settings 19 4 4 4 Battery settings 20 4 4 5 Battery ch...

Page 20: ...Front panel AC UPS GD 128x64 2 OMX76014 Rev A 5 1 DEFINITION OF THE OPERATING STATUS 25 5 2 ALARMS TROUBLESHOOTING 28 ...

Page 21: ...ements Menu Selection 10 Figure 6 Input Measurements Menu 10 Figure 7 Commands Menu Selection 12 Figure 8 Commands Menu Reset UPS 13 Figure 9 Alarms Menu Selection 15 Figure 10 Alarms Menu Device Status 15 Figure 11 Alarms Menu Log 16 Figure 12 Settings Menu Selection 18 Figure 13 Settings Menu Clock 22 Figure 14 Info Menu Firmware Versions 23 Figure 15 Home Page if alarms present 24 ...

Page 22: ...Front panel AC UPS GD 128x64 4 OMX76014 Rev A ...

Page 23: ...protected allows you to edit the parameters of the UPS to allow a high level of configurability to be obtained Further information If the information outlined here is insufficient contact the manufacturer of the device 2 PANEL FUNCTIONALITY The command panel of the UPS is used to Check the functional parameters of the device Display the events log Show the information on the device Change the oper...

Page 24: ...T PANEL The front panel of the rectifier is composed of an alphanumerical graphic display 20 configurable LEDs and 7 function keys that allow navigation A synoptic display shows the functional status of the device and the power flow Figure 1 Front panel ...

Page 25: ... all the leds Quickly pressing the key only switches on the leds configured in the colour configured Instead keeping the key pressed after 5 seconds all the leds in all colours switch on Silence the buzzer triggered by an alarm or anomaly Back to HOME menu Back to previous menu Scroll menu upwards Scroll menu downwards Select menu Confirm changes ...

Page 26: ... LED 4 GREEN Inverter OK RED Inverter not OK LED 5 GREEN Inverter static switch closed OFF Inverter static switch open LED 6 GREEN Output voltage OK RED Output voltage out of tolerance range LED 7 OFF Bypass static switch open ORANGE Bypass static switch closed LED 8 GREEN Alternate bypass mains in tolerance range OFF Alternate bypass mains fault LED 9 OFF Manual bypass disabled RED Manual bypass ...

Page 27: ...led on the display are as follows TEST MODE INVERTER OFF RECTIFIER OFF BYPASS FEEDS LOAD BYPASS NOT AVAILABLE INV NOT SYNCHRONISED UPS RUNNING From the Home Page you can browse through the menus clicking on one of the two arrows The main menus you can slide through are MEASUREMENTS COMMANDS ALARMS SETTINGS INFO For example pressing the bottom arrow you access the following screen Figure 4 Home Pag...

Page 28: ... On some menus for example the screen above the presence of multiple pages is indicated on the top right In these menus you can move from page to page using the arrow keys The list of all the measurements available is outlined below Menu Data displayed Accuracy INPUT Rectifier input voltage 1 1 V Rectifier input current 1 A Rectifier input frequency 0 1 Hz RECTIFIER Rectifier output voltage 0 1 V ...

Page 29: ...e measurement refers to the value between the phases 2 The battery measurements are only displayed for configuration with at least one battery installed 3 The measurements are only available for the configuration with 2 batteries installed 4 The measurements are only available for the configuration with 3 batteries installed 5 The residual energy is only available on special request 6 The temperat...

Page 30: ...top rapid recharge boost FORCED BOOST Start Stop timed rapid recharge AUTO MANUAL Start Stop manual charge BOOST TEST Boost battery test TEST FAST DISCH Rapid discharge battery test TEST MANUAL Manual battery test RESUME STARTUP Allows you to recover the start sequence RESET HISTORY 1 Allows you to reset the log 1 Password protected menu 2 The battery commands are only displayed for configuration ...

Page 31: ...ET is however necessary to reset normal conditions due to blocking conditions such as Maximum rectifier direct voltage output alarm A5 Alarm circuit error Alarm A31 Inverter switch off for maximum DC voltage The RESET command also has the function of acknowledging certain alarms or events The operator must press the RESET command to confirm the following alarms Safety timer for rapid recharge or m...

Page 32: ...d test decrease the output voltage from the buffer float charge up to the second level of battery minimum voltage monitoring the battery current Flat battery manual test allows the user to choose the minimum voltage level of the battery test and its duration during the output voltage test of the rectifier it will be set at 1V under the minimum voltage level of the battery test The test will be exc...

Page 33: ...tatus enabled on the machine The display of an alarm or status at a time You can scroll the list using the arrow keys Figure 10 Alarms Menu Device Status Each time an alarm activates the page is updated An acoustic signal indicates a new anomaly has occurred in any case the buzzer can be silenced pressing the key BUZZER Automatic alarm reset For most of the alarms except those described in the par...

Page 34: ...rence to the number of total events saved yyy maximum number equal to 500 On first access the event displayed will be more recent as indicated on the top right 001 yyy You can move between saved events using the arrow keys Display and saving mode of the alarms and statuses In the alarm and statuses menus the latter are always displayed in increasing order based on the numerical code The alarms are...

Page 35: ...everse polarity A54 CAN Inverter disconnected 7 A23 Battery test failed 2 A55 Lost redundancy 7 A24 Q11 open 3 A56 A25 Rect CAN error 1 A57 A26 Rect parallel fault 1 A58 A27 A59 A28 SBCB open 3 A60 A29 ELCB open 3 A61 Internal error A30 Rectifier off by user A62 Start sequence block A31 Rect control error loop A63 EEPROM error A32 A64 Common alarm STATUS STATUS DESCRIPTION STATUS STATUS DESCRIPTIO...

Page 36: ... Allows changing the inverter switch off minimum voltage threshold OUTPUT Allows output tolerance parameters to be changed BATTERY 1 Allows setting the data of the battery including the automatic test parameters BATT CHARGE 1 Allows setting the float charge parameters with buffer manual and rapid DC VOLTAGE Allows changing the rectifier output voltage tolerance MODBUS 1 Allows setting the ModBus c...

Page 37: ...he Inverter Settings menu allows changing the acceptability intervals for voltage and frequency of the inverter output Drop down menu Data displayed MIN VDC INPUT Inverter input minimum voltage Sets the minimum input voltage of the inverter under this threshold the inverter will switch off 4 4 3Output Settings The Output Settings menu allows changing the acceptability intervals for voltage and fre...

Page 38: ...loating charge sets the threshold for alarm A9 MIN LEV 1 Battery level min 1 First level sets the threshold for the alarm A16 MIN LEV 2 Battery level min 2 Second level sets the threshold for the alarm A17 MIN LEV 3 Battery level min 3 Third level sets the threshold for the alarm A18 AUTOM TEST Automatic test parameters setting ENABLE DISABLE Enables disables the automatic test Enables automatic t...

Page 39: ...t charge mode FORCED DURATION Timed boost charge Sets the duration of timed boost charge DURATION FORCED Standby time Boost charge floating charge Sets the boost charge standby time for floating charge CURRENT B F Boost charge current floating charge Sets the boost charge current threshold at the floating charge CURRENT F B Floating charge current Boost charge Sets the floating charge current thre...

Page 40: ...gs There are two ModBus Setting menus which allow you to set the ModBus communication parameters for port 1 and 2 Drop down menu Description Address Sets the ModBus slave address from 1 to 247 Transmission speed Sets the transmission speed of the data on the communication serial port Mode Sets the parity and number of bits for stoppage on the communication serial port 4 4 8Clock settings The Clock...

Page 41: ...NS Firmware Versions Firmware version of the UPS Static Micro Controller Rectifier DSP and Inverter DSP Front panel firmware version MODBUS 1 Displays the ModBus parameters of integrated port 1 MODBUS 2 Displays the ModBus parameters of integrated port 2 DATE TIME Displays the date and time set on the rectifier The Firmware Versions screen follows Figure 14 Info Menu Firmware Versions ...

Page 42: ...d To have a list of the active alarms and the active statuses you can access the Alarms menu Figure 15 Home Page if alarms present Danger of injuries due to electric shock Before carrying out any operation on the UPS ensure you have complied with all the safety precautions All work on the unit must be carried out by qualified staff You can access internal components only having disconnected the de...

Page 43: ...harge level Status S5 MANUAL CHARGE Description The rectifier battery charger is working in manual mode Operating condition The output direct voltage is adjustable using the manual charge potentiometer Status S6 BATTERY TEST Description The rectifier battery charger is executing a battery test Operating condition The output direct voltage is different based on the test request Status S7 FLOATING I...

Page 44: ...ondition is enabled when the output current of the rectifier is correctly shared among the rectifiers Status S13 BOOST INHIBITION Description The boost function is inhibited Operating condition The rectifier does not allow activation of the rapid charge Status S14 INVERTER ON Description Inverter on Operating condition The inverter is on Status S15 INVERTER OK Description The inverter is working p...

Page 45: ...hines The inverter is synchronised with the MASTER output Status S19 BYPASS OK Description The bypass mains is available and in tolerance Operating condition The bypass mains is available and in tolerance Status S20 BYPASS FEEDS LOAD Description The load is powered by the bypass Operating condition The bypass network is available and in tolerance the bypass static is closed and the switch is close...

Page 46: ... causes Cooling system failure Rectifier bridge irregular conduit Solutions 1 Check the conduit conditions on all three input phases 2 Check the fans and the cooling system are working properly 3 If the alarm persists contact our technical support service Alarm A4 RECTIFIER OVERLOAD Description The current sensor has detected rectifier output overload If the alarm persists thermal image protection...

Page 47: ...ERY Description The battery voltage on floating charge measured has surpassed the higher threshold value Possible causes Circuit fault of control or measurement Solutions 1 Check the actual value of the output direct voltage measured 2 If the alarm persists contact our technical support service Alarm A9 MINIMUM FLOAT BATTERY Description The battery voltage on floating charge measured has surpassed...

Page 48: ... is open Possible causes Output switch open Switch auxiliary contact faulty Solutions 1 Check the switch auxiliary contact is working 2 If the alarm persists contact our technical support service Alarm A15 FLAT BATTERY Description Battery is flat Possible causes Battery flat due to mains fault Rectifier fault Solutions 1 Check which alarms are present and execute the indicated procedures 2 If the ...

Page 49: ... 2 Check which alarms are present and execute the indicated procedures 3 If the alarm persists contact our technical support service Alarm A19 EPO PRESSED Description The EPO button was pressed Possible causes EPO button pressed Button auxiliary contact fault Solutions 1 Check the emergency button auxiliary contact is working 2 If the alarm persists contact our technical support service Alarm A20 ...

Page 50: ... support service Alarm A23 BATTERY TEST FAILED Description The battery has not passed the automatic test Possible causes Battery disconnected The battery is not working properly Solutions 1 Check the battery status 2 If the alarm persists contact our technical support service Alarm A24 Q11 OPEN Description Switch Q11 open only in configurations using Q11 Possible causes Battery Q11 open Solutions ...

Page 51: ...vice Alarm A29 ELCB OPEN Description The ELCB emergency line switch is open Possible causes ELCB emergency line switch open Switch auxiliary contact faulty Solutions 1 Check the switch auxiliary contact is working 2 If the alarm persists contact our technical support service Alarm A30 RECTIFIER OFF BY USER Description Rectifier manually switched off Possible causes Rectifier switched off from pane...

Page 52: ...e Possible causes Out of tolerance input DC voltage Check output voltage of the rectifier and the battery Solutions 1 Check the points in the Possible causes 2 If the alarm persists contact our technical support service Alarm A36 INVERTER HIGH TEMPERATURE Description The temperature of the inverter heat sink exceeds the higher threshold value Possible causes Cooling system failure Inverter bridge ...

Page 53: ...B OPEN Description The external output switch is open Possible causes External output switch open Switch auxiliary contact faulty Solutions 1 Check the switch auxiliary contact is working 2 If the alarm persists contact our technical support service Alarm A41 MBCB CLOSED Description The MBCB bypass switch is closed Possible causes Manual bypass switch MBCB closed Switch auxiliary contact fault Sol...

Page 54: ...ck the loads connected to the output to the inverter and if necessary reduce the load 2 If the alarm persists contact our technical support service Alarm A45 BYPASS NOT OK Description Bypass not available or voltage or frequency of bypass out of tolerance Possible causes Voltage out of limit permitted Frequency out of limit permitted Bypass cyclic direction incorrect Solutions 1 Check the bypass v...

Page 55: ...nical support service Alarm A49 MINIMUM OUTPUT VOLTAGE Description The output voltage is under the minimum tolerance threshold Possible causes Inverter bridge switched off or faulty Control logic malfunction Solutions 1 If the inverter is off switch it on 2 If the alarm persists contact our technical support service Alarm A50 MAXIMUM OUTPUT VOLTAGE Description The output voltage is over the maximu...

Page 56: ...hnical support service Alarm A54 CAN INVERTER DISCONNECTED Description The inverter parallel cable is not connected Possible causes Parallel cable not connected properly Solutions 1 Check the cable connection is correct 2 If the alarm persists contact our technical support service Alarm A55 LOST REDUNDANCY Description The parallel inverter number is not sufficient to guarantee the minimum redundan...

Page 57: ...ical support service Alarm A63 EEPROM ERROR Description The control unit detected an error of the parameters saved in E2PROM Possible causes Wrong parameters entered during programming Solutions 1 Contact our technical support service Alarm A64 COMMON ALARM Description UPS common alarm Possible causes There is at least one alarm from the UPS logic Solutions 1 Check which alarms are present and exe...

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Page 59: ...oved Lingua Language Pagina Page di Pag of Pag A First Issue 10 09 20 E Parducci M Mancini E 1 8 Codice Code OMX76015 START UP SHUT DOWN MANUAL BYPASS Index 1 INTRODUCTION 3 2 START UP PROCEDURE 4 3 SHUT DOWN PROCEDURE LOAD NOT SUPPLIED 6 4 MANUAL BYPASS PROCEDURE 6 5 START FROM MANUAL BYPASS MODE 7 ...

Page 60: ...Start up shut down manual bypass 2 OMX76015 REV A ...

Page 61: ...hapter read the instructions carefully to avoid possible harm to people or damage to property due to wrong manoeuvres CAUTION Wrong execution of the manoeuvres can cause harm to people and damage to property The image on the bottom represents a screen printed representation which includes the leds of the synoptic panel ...

Page 62: ...itches No LCD MESSAGE ACTION UPS BEHAVIOUR 1 BLANK Close RICB 2 UPS STARTUP PLEASE WAIT The control unit is powered All the LEDs of the front panel switch on for a second 3 RECTIFIER STARTUP PLEASE WAIT The UPS control unit is in standby for the power mains to work properly The green indicator light of LED 1 is on 4 RECTIFIER STARTUP MOVE SELECTOR ON Move selector if present If the rectifier ON OF...

Page 63: ...IGBT bridge starts to modulate and the output voltage of the inverter reaches the nominal value The green indicator light of LED 5 is on The inverter static is closed and the green indicator light of LED 6 switches on 14 BYPASS STARTUP PLEASE WAIT The UPS control unit is going to start the emergency network 15 BYPASS STARTUP CLOSE ELCB Close ELCB if present 16 BYPASS STARTUP CLOSE SBCB Close SBCB ...

Page 64: ...TION UPS BEHAVIOUR 1 Position the NORMAL BYPASS switch on BYPASS The load is transferred to the bypass static switch The LED 6 is off while the orange indicator light of LED 8 is on 2 Close MBCB The load is powered by the main network using the manual bypass circuit switch The bypass static switch is still closed 3 Open RICB The rectifier is off while the inverter is still on being powered by batt...

Page 65: ...r to close it 6 RECTIFIER STARTUP PLEASE WAIT The rectifier output direct voltage increases up to the nominal value The micro processor checks all the start parameters are working properly The green indicator light of LED 2 and LED 3 are on 7 RECTIFIER STARTUP CLOSE Q11 Close Q11 if present If switch Q1x is present and is open the display asks to close it once rectifier start up is complete 8 BATT...

Page 66: ...OVE SELECTOR ON Move selector if present If the inverter ON OFF selector is present and in the OFF position the display asks for its movement to the ON position 19 INVERTER STARTUP PLEASE WAIT The inverter IGBT bridge starts to modulate and the output voltage of the inverter reaches the nominal value The green indicator light of LED 5 is on 20 INVERTER STARTUP MOVE BYPASS SWITCH Move the NORMAL BY...