IOM-320222 Equipment and Battery Information

Proj ect:: Project Custo Cus tomer mer::

MEROWE MEROW E DAM ALST AL STOM OM HYD HYDRO RO FRANC FRANCE E

P.O.: 4500035965 DUAL UPS Apo Apody dys2 s2 60kVA 220VDC 220VDC 3x230V

Commissioning,

Operation and Maintenance manual

Chloride ref: DT320222 Proj ect ID: 101 101033 033 / 05 05 OF: W019645

COMMISSIONING,

OPERATION AND MAINTENANCE MANUAL AL A L STOM HYDRO FRANCE FRA NCE MEROWE MEROWE DAM DA M PROJECT P.O. 4500035965 DUAL UPS Apodys2 60kVA 220VDC 3x230V CHLORIDE REF : DT 320222 PROJECT : 101033 / 05 OF : W019645

CHLORIDE INDUST INDUSTRIAL RIA L SYSTEMS EM S

LIST OF REVISIONS ISSUE

DATE

REVISED PAGES

00

17/12/10

00

Page 2 of 65

CHLORIDE INDUSTRIAL SYSTEMS

LIST OF CONTENTS

Title

Page

1. SAFETY

7

1.1. GENERAL

7

1.2. NATURE OF HAZARD

8

1.3. SAFETY PRECAUTIONS

8

1.4. EMERGENCY ACTION AND TREATMENT

9

1.5. SAFETY - VENTED LEAD ACID BATTERIES

10

1.6. COSHH STATEMENT

12

2. DESCRIPTION AND OPERATION

14

2.1. DESCRIPTION

14

2.2. TOPOLOGY

14

2.3. OPERATING MODES

17

3. SYSTEM SPECIFICATION

22

3.1. CHARACTERISTICS

22

4. INSTALL ATION

23

4.1. HANDLING ON ARRIVAL

23

4.2. STORAGE

24

4.3. PUTTING INTO INSTALLED POSITION

24

4.4. CABLE ENTRIES

25

4.5. TERMINAL CONNECTIONS

25

4.5.1. Phase rotation

25

4.5.2. Battery

25

4.5.3. Neutral

25

4.5.4. Earth

25

4.6. VENTILATION

26

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4.7. BATTERY-VENTED LEAD ACID

26

4.8. BATTERY INSTALLATION

26

5. OPERATING INSTRUCTIONS

28

5.1. LIGHT EMITTING DIODES (LEDS)

29

5.2. DISPLAY

30

5.3. CONTROL PUSH-BUTTONS

31

5.4. PRESENTATION OF THE MENUS

32

5.5. GENERAL MENU

32

5.6. UPS BLOCK MENUS

33

5.7. CONTROL PANEL MENUS

36

5.8. CHANGE CHARGER MODE

42

5.9. MEASURES, FAULTS AND WARNINGS

43

5.10. HEADING

43

5.11. OPERATING INSTRUCTIONS

46

5.11.1. FIRST START-UP

46

5.11.2. MAINTENANCE PROCEDURE

47

5.11.3. TRANSFER TO MAINTENANCE FOR A STAND-ALONE INVERTER

49

5.11.4. RETURN FROM MAINTENANCE FOR A STAND-ALONE INVERTER

49

5.11.5. GLOBAL MAINTENANCE PROCEDURE

50

5.11.6. BLACK START PROCEDURE

50

6. ROUTINE MAINTENANCE

51

6.1. GENERAL

51

6.2. ONCE A WEEK

51

6.3. ONCE A MONTH

51

6.4. AT LEAST 4 TIMES PER YEAR

52

6.5. ANNUALLY

52

6.6. FANS

52

7. FAULT DIAGNOSIS

53

7.1. CHARGER DISPLAY MENU

54

7.2. CHARGER DEFAULTS

55

7.3. CHARGER VOLUNTARY STOPPED

56

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7.4. CHARGER WARNING

56

7.5. BATTERY FAULT

57

7.6. BATTERY WARNING

57

7.7. INVERTER DISPLAY MENU

58

7.8. INVERTER FAULTS

59

7.9. INVERTER VOLUNTARY STOPPED

60

7.10. INVERTER WARNING

60

7.11. RESERVE WARNING

61

7.12. AC LOAD/ STATIC SWITCH FAULT

61

7.13. AC LOAD/STATIC SWITCH WARNING

62

8. SPARE PARTS

63

8.1. GENERAL NOTES

63

9. DRAWINGS

64

9.1. GENERAL NOTES

64

10. ATTACHMENTS

65

10.1. BATTERY MANUAL

65

Page 5 of 65


LIST OF ILLUSTRATIONS

Title

Page

Figure 2.1 : Blo ck Diagram

14

Figure 2.2 : Voltage Current Characteristi c of Charger

15

Figure 2.3 : Normal Mode

17

Figure 2.4 : Primary AC Supply Fail Mode

18

Figure 2.5 : DC Alarms During Primary Supply Failu re

18

Figure 2.6 : Reserve to Load

19

Figure 2.7 : Maint enance Bypass Mode

20

Figure 2.8 : One UPS Fail

21

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1. SAFETY Title

Page

1.1. GENERAL

7


8

1.3. SAFETY PRECAUTIONS

8

1.4. EMERGENCY ACTION AND TREATMENT

9

1.5. SAFETY - VENTED LEAD ACID BATTERIES

10

1.6. COSHH STATEMENT

12

1.1. GENERAL

Read this section and this manual before starting work on any part of the system. When working on live equipment (batteries are always live), a second person who is aware of all safety precautions and emergency actions should be present at all times. It is the responsibility of each individual to be aware of national legislation, local legislation and site rules governing safety and working practices. If in doubt ask. Use only good quality insulated tools and accessories, properly maintained and calibrated instruments, and suitable and adequate supports and lifting equipment.

It is essential that all safety instructions are strictly observed. Note :

A note in this style is used to emphasise an important point in the text

CAUTION :

USED TO PREVENT DAMAGE TO EQUIPMENT.

WARNING

A WARNING IS USED TO ALERT PERSONNEL TO HAZARDS TO PERSONAL SAFETY.

Installation, maintenance and repair of the equipment and batteries should only be undertaken by trained, experienced and authorised electrical personnel. The handling, installation and maintenance of the battery associated with this equipment must be in accordance with the instructions and safety precautions published by the battery manufacturer.

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ELECTRICAL ENERGY can be supplied from the battery, the charging equipment, the AC supply or the external alarm or auxiliary control terminals. The battery terminals are LIVE at all times. A short circuit, even on a discharged battery, will result in a high current which can cause personal injury, fire or damage to the battery or battery cables.

BATTERY ELECTROLYTE in ALL batteries is dangerous and can cause severe burns if allowed to come into contact with the skin or eyes. It will also attack clothing and some paint finishes and metals. LEAD ACID batteries contain sulphuric acid solution. VENTED or FLOODED cells (Planté, Flat Plate and tubular lead acid or cells) contain free liquid electrolyte which can spill if the cell is overturned, overfilled or the cell container is broken.

HYDROGEN and OXYGEN are given off at the cell plates during charging and can be present at other times, particularly if cells are moved or shaken. Hydrogen in conjunction with air or oxygen can be explosive in the presence of sparks or flame.

In vented cells the hydrogen and oxygen are vented to the air. Battery cells or cellblocks can be very heavy and often have to be moved to positions with difficult access. When working on batteries with many cells or blocks, muscle strain may occur suddenly or after battery installation is complete. 1.3. SAFETY PRECAUTIONS

Use only insulated tools, particularly when connecting a battery. Stand on a rubber mat. Personal effects of metal such as rings, watches, bracelets and necklaces which may cause a short circuit and metal objects (pens, tools etc) which may fall from open pockets while bending over batteries or chargers should be removed. Isolate all AC supplies, auxiliary supplies and the battery (open isolator, remove battery fuses or remove a battery link) before working on the equipment. Never handle a component or assembly without personally confirming that no voltage is applied or present. If it is necessary to make adjustments with the equipment connected to the AC supply and/or the battery, remove only those protective covers which are absolutely necessary for access. Always use eye protection and rubber gloves when handling cells. Handle cells with care, ensuring they are kept upright. Use properly constructed staging or platforms as a resting-place close to the final position and enlist assistance with large cells or large numbers of cells. Keep the back straight and upright when lifting cells. Use only proper lifting techniques. It is recommended that battery rooms should be provided with an eyewash bottle filled with a fresh saline solution and a supply of clean water with means of directing on burns and splashes. There should also be a safety shower in the battery room. Do not smoke. Do not use open flames. Avoid creating an arc or sparks when working on this equipment. Avoid wearing clothing which is susceptible to discharge of static electricity.

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Always use pure distilled or de-ionised, de-mineralised water when topping up vented battery cells. Do not use the same topping up apparatus or hydrometer for both nickel cadmium alkaline and lead acid cells. Even small quantities of electrolyte transferred will damage or destroy cells. After work is complete, refit all protective covers and close and lock all doors. 1.4. EMERGENCY ACTION AND TREATMENT

ELECTRICAL SHOCK - Immediate action is essential. Severe electric shock may affect heart action and breathing.

Make sure it is safe to approach. If the casualty is in contact with a live conductor, isolate by switching off the supply. See section 5 "EMERGENCY SHUTDOWN". If this is not possible, or it is doubtful whether the system is electrically isolated, stand on dry insulating material and pull or push the casualty clear using dry insulating material, e.g. wood, plastic, fabrics etc. If necessary give artificial respiration. Seek the assistance of others to summon medical attention.

ELECTRICAL BURNS - Apply a dry sterile dressing.

ELECTROLYTE CONTACT - EYES - Irrigate the eyes with a saline solution. If saline solution is not available wash with clean running water for at least 10 minutes

SKIN - Wash skin burns with plenty of clean water. Remove any contaminated clothing. Cover the area with dry gauze. IN ALL CASES SEEK IMMEDIATE MEDICAL ATTENTION.

ELECTROLYTE SPILLAGE - These should be washed away using large volumes of clean water or mopped up using absorbent material which should then be sealed in secure containers and sent to a recognised chemical disposal company. Operatives handling spillage should wear adequate clothing including eye protectors and gloves. Electrolyte will attack many fabrics. In the event of spillage on clothing, the garments should be removed and washed thoroughly in large volumes of clean water or discarded.

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1.5. SAFETY - VENTED L EAD A CID BA TTERIES

WARNING :

IN CASES WHERE THE UNIT IS NOT BEING USED, E.G. DURING MAINTENANCE, IT IS RECOMMENDED TO DISCONNECT THE BATTERY TO AVOID IT DISCHARGING AND BEING DAMAGED.

Nature of hazard. The hazards are Risk of electric shock Risk of electric burns Risk of chemical burns Risk of poisoning Risk of explosion from charging gases. ELECTRIC SHOCK An electric shock from d.c. is more damaging than a shock from a.c. of the same voltage because d.c. has the characteristics "NO-LET-GO" due to the muscles being contracted by the single direction of flow of the current. Risk of d.c. shock between battery terminals and earth is limited in this equipment by incorporating double wound transformers in both the inverter and rectifier so that the entire d.c. link is floating. Anyone coming into contact with it accidentally will experience only the equalising charge which is unlikely to cause injury. However, this protection could be defeated if, for example, a metal tool were to fall between a battery terminal and earth (wooden battery stands are preferred for this reason). The system would continue to perform normally but the battery and d.c. link would be in a dangerous condition. Where an earth fault detector is fitted this will raise an alarm. The principle of operation is to verify that the d.c. positive and negative rails are respectively at symmetrically voltage with respect to earth. Any abnormal short, event of high resistance, will disturb this symmetry.

WARNING:

IF THE EARTH FAULT ALARM IS ACTIVE DO NOT CARRY OUT MAINTENANCE ON THE BATTERY.

The other possibility for electric shock would be if a person were to come into contact with two distant battery terminals in the same string. This possibility is avoided by arranging for the battery layout to be configured so that the maximum distance separates the highest voltage differences.

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ELECTRIC BURNS The prospective short circuit current from a battery is very big. So even a modest cell will deliver over a thousand amps into a short circuit such as a metal watchstrap or an uninsulated tool. The battery assembly may consist of well over a hundred cells in series in many applications so the potential for serious injury exists.

WARNING:

REMOVE METAL RINGS AND WATCHSTRAPS WHEN WORKING WITH BATTERIES. USE PROPERLY INSULATED TOOLS.

CHEMICAL BURNS FROM ELECTROLYTE The electrolyte is sulphuric acid. It is corrosive to clothing and to living tissue. Even minute traces can cause irritation and make holes in clothes. When preparing electrolyte or topping up batteries wear full protective clothing. Protect the eyes nose and mouth either with goggles and facemask or wear a full-face visor. Protect the body with all enclosing overalls. Protect the hands with gauntlets. Protect the feet with boots that have sealed seams. Stitched seams can allow seepage. An eyewash must be available and any splashes must be flooded with copious amounts of water or saline solution to dilute the acid. Seek medical attention. Neutralising agent must be on hand. Scatter it on any acid spills. NOTE : Lead acid electrolyte is acidic, Nickel Cadmium electrolyte is alkaline so different neutralising agents are needed.

POISONING If electrolyte is swallowed it will be corrosive to internal organs. Medical opinion is divided on whether to attempt to dilute it with milk or water or to do nothing until medical help arrives. Therefore at the outset consult the local medical authority who would have to deal with an emergency and post suitable notices in the battery room.

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EXPLOSION During the recharge cycle the voltage of the battery will be raised above the gassing voltage Hydrogen and oxygen will be given off. Risk of explosion exists when the concentration of hydrogen in air is more than 3.8%. Therefore the battery room must be adequately ventilated. Volume flow for the required air change can be calculated as follows; Q = 55 x N x I Where

(for vented cells)

Q = The required volume flow in litres / hour N = The number of cells I = The maximum end of charge current This calculation applies to normal land based installations. Shipboard installations need twice this calculated flow rate in order to comply with maritime regulations. If this damages the battery casing there can be a flood of battery electrolyte with risk of acid burns to the feet of anyone caught in the way. Therefore approach any battery explosion with caution. The battery room must be adequately ventilated to disperse gases, particularly during Charge mode or Boost charge. Preclude all sources of ignition. Do not smoke. Ensure all electrical connections between cells are securing and tight to prevent sparking. 1.6. COSHH STATEMENT

When this equipment finally reaches the end of its useful life it must be disposed of with due care. It contains material which could present a variety of hazards to the environment and to living organisms if not dealt with properly. Contact a reputable disposal service. The following information is a guide to the disposal problems as known at the time of manufacture. . BATTERY ELECTROLYTE Lead Acid batteries contain sulphuric acid. It must never be washed into public or general purpose drains. BATTERY PLATES The plates will be lead or a lead oxide. The plates may be porous and impregnated with Sulphuric acid.

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SEMICONDUCTORS There are large semiconductors mounted on extruded aluminium, finned heat sinks. These are thyristors and diodes. They are all doped silicon semi conductors incorporating P type and N type silicon. These materials will be hermetically sealed inside discrete devices. Some contain silicon, copper and other metals and metallic compounds including beryllium. They are sealed and must not be opened. If the seal is broken, use protective gloves when handling the semiconductors and seal them into tough plastic bags before disposal. PRINTED CIRCUIT BOARDS The circuit boards are constructed of fibreglass and resin board with copper track. The components include metal film resistors, silicon transistors, capacitors (both bipolar and electrolytic). Silicon diodes, micro chips type CMOS, high speed CMOS and TTL. INDICATOR PANEL The indicator panel includes light emitting diodes and liquid crystal displays. WIRES AND CABLES The internal wiring is of copper bar and copper wire covered with flame retardant PVC. HEATSINKS These are of aluminium. METAL PARTS These are of mild steel painted with an epoxy resin paint finish. CAPACITORS These contain no PCBs or similarly toxic materials. Capacitors are sealed and must not be opened. If the seal is broken use protective gloves when handling the capacitors and seal them into tough PVC bags before disposal.

Restricted Sales Distribution WARNING: This is a product for restricted sales distribution to informed partners. This product must be operated by only personnel authorised to enter restricted access location. Installation restrictions or additional measures may be needed to prevent disturbances.

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2. DESCRIPTION AND OPERATION Title

Page

2.1. DESCRIPTION

14

2.2. TOPOLOGY

14

2.3. OPERATING MODES

17

2.1. DESCRIPTION

The Uninterruptible Power System (UPS) is designed to supply AC sinusoidal, electric power that cannot be interrupted by abnormal occurrences on the public electricity supply. It is designed on the "double conversion" principle whereby the public supply is used to power a battery charger in order to store energy to be used during a power cut. This DC supply is then inverted within the equipment to a pure quality sine wave which is immune to defects on the incoming AC supply. 2.2. TOPOLOGY

The System consists of two UPS equipments connected in parallel to share the load. Each unit on its own is rated to support the full load. If either one fails then the surviving unit will sustain the full load without break. RESERVE TRANSFORMER RESERVE SUPPLY STATIC SWITCH

CHARGER 2

INVERTER 2

STATIC SWITCH

BATTERY CHARGER 1

INVERTER 1

STATIC SWITCH

BATTERY

Figure 2.1 : Block Diagram

Page 14 of 65


Each equipment consists of four major parts, see Figure 2.1. Block Diagram, the Rectifier/ Charger, the Battery, the Inverter and the Static Switch. The reserve is through a transformer. VOLTAGE Boost Charge Float

CURRENT

Figure 2.2 : Voltage Current Characteristic of Charger RECTIFIER/CHARGER Converts the Primary AC supply to a regulated D.C. voltage which charges the battery, powers the inverter and therefore the load. It operates in four possible modes. Mode 1.

FLOAT MODE. This is the normal mode. It is a constant-voltage charge mode so battery charge current will tend to taper off to near zero as the battery becomes fully charged. The voltage chosen is that value at which the internal losses are compensated by the charge current into a charged battery. The battery is maintained fully charged yet remains below gassing voltage so that the rate of loss of electrolyte is negligible.

Mode 2.

AC SUPPLY FAIL MODE. When the power to the charger is interrupted the charger stops and without any switching taking place or operator intervention the battery supplies the inverter and hence the load.

Mode 3.

CHARGE MODE Automatically selected when the AC supply is restored. Slightly higher constant voltage charge to shorten the time to recharge the battery. It is controlled by two timers. Timer No.1 selects CHARGE MODE after an AC supply fail has lasted more than a minimum specified time. Timer No. 2 terminates CHARGE MODE after a specified duration. It can be engaged or terminated manually by an operator by means of push buttons inside the cubicle.

Mode 4.

BOOST MODE Very high constant voltage charge. Intended for use at commissioning to complete the forming process of the battery plates. It can only be engaged manually, by an operator. It is terminated either manually or by an inbuilt clock. For safety the battery charging current limit threshold reduced during BOOST mode.

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BATTERY This stores energy from the charger to be used during a power cut when it will discharge to power the inverter and load. The autonomy of the system during a mains fail depends on the amp-hour capacity of the installed battery. INVERTER Converts the d.c. power to sinusoidal a.c. power. Uses a high frequency pulse width modulation (PWM) switching technique to achieve low distortion sinewave power while retaining good transient response voltage regulation. Operates in the following modes. Mode 1. NORMAL Constant voltage output regulated to ±1% for power loading between 0 and 105%. Mode 2.

OVERLOAD. 105% to 150%.of rated load. Constant voltage output but 10 minute timer initiated which upon expiring will shutdown the inverter. This is long enough to cope with start up surges and current inrushes in the load.

Note. When the load exceeds 105% the static switch will normally transfer the load to reserve (if available) so inverter overloads should be a rare occurrence. Mode 3.

CURRENT LIMIT. When the load is 150% or more of nominal then the inverter changes to a constant current characteristic to protect itself. This can result in the output voltage falling drastically. If reserve is available it will have transferred to reserve immediately instead. If transfers are inhibited for any reason then the inverter will continue in current limit until either the load subsides to normal or the 10 minute timer expires.

STATIC SWITCH The static switch is an automatic, solid state, changeover switch having a make-before-break action so that no interruption to the load occurs. Therefore the inverter will be permanently synchronised to the reserve in order to avoid phase jumps or even phase reversals to the load at the instant of transfer. It monitors the operating status of the various parts of the UPS and the logic will select one of two modes either INVERTER-TO-LOAD or RESERVE-TOLOAD. Mode 4.

INVERTER TO LOAD. This is the normal mode for the unit and is automatically selected whenever possible.

Mode 5.

RESERVE TO LOAD. Transfer to reserve occurs automatically when certain specified abnormal conditions prevail. It returns to inverter 10 seconds after the alarm conditions clear.

It has no moving parts, the active components being switching thyristors to preclude arcing and sparking during switching for long term reliability. Note transfers can take place at any place in the cycle, they do not have to be at a zero crossover.

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MAINTENANCE BYPASS For safety during maintenance and repair a wrap-around manual bypass is incorporated into the equipment. It can be selected only by the operator not by the control logic. It provides safety isolation of major internal parts for purposes of repair and maintenance. 2.3. OPERATING MODES

NORMAL RESERVE TRANSFORMER RESERVE SUPPLY STATIC SWITCH

CHARGER 2

INVERTER 2

STATIC SWITCH

BATTERY CHARGER 1

INVERTER 1

STATIC SWITCH

BATTERY

Figure 2.3 : Normal Mode The two inverters power the load in parallel sharing the load between them. They are each synchronised to the reserve supply.

Page 17 of 65


PRIMARY AC SUPPLY FAIL MODE RESERVE TRANSFORMER RESERVE SUPPLY STATIC SWITCH

CHARGER 2

INVERTER 2

STATIC SWITCH

BATTERY CHARGER 1

INVERTER 1

STATIC SWITCH

BATTERY

Figure 2.4 : Primary AC Supply Fail Mode The reserve supply may or may not be available depending on the configuration of supplies into the UPS. Each charger stops and their respective batteries each power the inverter and hence the load. The DC voltage falls and the following alarms occur MAINS FAIL

FLOAT VOLTAGE

INVERTER SHUTDOWN IMMINENT

LOW DC TRIP

Figure 2.5 : DC Alarms During Primary Supply Failure When the primary AC supply returns the charger will start in Float Mode after a short AC supply failure or Charge Mode after a long AC supply Failure.

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RESERVE-TO-LOAD MODE RESERVE TRANSFORMER RESERVE SUPPLY STATIC SWITCH

CHARGER 2

INVERTER 2

STATIC SWITCH

BATTERY CHARGER 1

INVERTER 1

STATIC SWITCH

BATTERY

Figure 2.6 : Reserve to Load mode is selected if: The output overload is 105% or more returning to the inverters when it falls below 100% The inverters stop The inverters are in current limit The MAINTENANCE switch is operated. Once on reserve it will wait ten seconds after all alarms have cleared before returning to inverter.

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MAINTENANCE BYPASS MODE Used by Maintenance Engineer to facilitate safe maintenance. RESERVE TRANSFORMER RESERVE SUPPLY STATIC SWITCH

CHARGER 2

INVERTER 2

STATIC SWITCH

BATTERY CHARGER 1

INVERTER 1

STATIC SWITCH

BATTERY

Figure 2.7 : Maintenance Bypass Mode

CAUTION:

INDISCRIMINATE OPERATION OF THE MAINTENANCE SWITCH MAY JEOPARDISE THE LOAD AND THE UPS. SEE SECTION 5. OPERATING INSTRUCTIONS.

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ONE UPS FAIL RESERVE TRANSFORMER RESERVE SUPPLY STATIC SWITCH

CHARGER 2

INVERTER 2

STATIC SWITCH

BATTERY CHARGER 1

INVERTER 1

STATIC SWITCH

BATTERY

Figure 2.8 : One UPS Fail If one UPS fails, it will be isolated by its own static switch. The surviving UPS will continue to support the load without break.

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3. SYSTEM SPECIFICATION Title 3.1. CHARACTERISTICS

Page 22

3.1. CHARACTERISTICS



Please see test reports hereunder.

Page 22 of 65


4. INSTALLATION Title

Page


23

4.2. STORAGE

24

4.3. PUTTING INTO INSTALLED POSITION

24

4.4. CABLE ENTRIES

25

4.5. TERMINAL CONNECTIONS

25

4.5.1. Phase rotation

25

4.5.2. Battery

25

4.5.3. Neutral

25

4.5.4. Earth

25

4.6. VENTILATION

26

4.7. BA TTERY-VENTED LEAD ACID

26

4.8. BA TTERY INSTALLATION

26


Unpack the equipment. Take care not to short circuit battery terminals together. Do not discard keys, battery connectors or accessories when disposing of packing materials. The cubicle keys will be in a bag taped to the cubicle door. Check the contents against the consignment note. The equipment has a rating plate normally affixed inside the door panel at the front which will identify the cubicle. Report immediately to the carrier and supplier if anything is missing or damaged. Delay in reporting may invalid claims for free repair or replacement. NOTE : The battery and equipment cubicle often arrive separately.

The cubicle and battery must be handled with care, keep them upright. Do not drop or subject them to impact. Cubicles are often top heavy with offset centres of gravity. The transit case is designed to be handled by a fork lift truck. Note the centre of gravity is often offset and cubicles may be top heavy, so take care to position the lift forks safely. Page 23 of 65


The equipment may be lifted by crane. It will be necessary to pass slings underneath the cubicle. The slings should be positioned under the extremities of the cubicle with safety straps to prevent them slipping towards the centre when under vertical tension. Also protect protrusions such as meters and switches from accidental damage from the lifting slings. 4.2. STORAGE

The cubicle should be stored in a clean dry environment. Although it is designed to operate in an ambient of 0°C to 40°C it can be stored in temperatures as low as –20°C. If it is to be stored for a long period of time some packing will be needed to prevent dirt getting inside through grilles and openings. When storing or shipping batteries at sub-zero temperatures the electrolyte must not be allowed to freeze otherwise mechanical damage can occur to the plates. Freezing occurs at about –20°C. Batteries should be maintained fully charged as this keeps the freezing point low. Follow the manufacturer's instructions. 4.3. PUTTING INTO INSTALLED POSITION

The equipment will have to be lifted from its pallet and manoeuvred into position. Note that battery cubicles are extremely heavy and adequately strong lifting gear is needed. Once in position adjacent cubicles should be fastened to each other by means of through bolts (these are provided inside plastic bags inside the cubicles), and to the floor using anchor bolts. Before fitting each anchor bolt, level the cubicles for both horizontal and vertical planes as required using incompressible shims. The procedure for fixing the panels together is as follows: Take the kit comprising of 4 screws and nuts (HM6 x 70mm) Remove the 2 transfer screws on the separating panel But the cubicles together holding the separating panel in place. The separating panel is sandwiched between the cubicles Take the 4 screws and open the panel doors Put the screws through the holes in the uprights which go through the separating panel. There are 2 at the top and 2 at the bottom. Put the nut on the screw and tighten.

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4.4. CABL E ENTRIES

Refer to the general arrangement drawings for cable entry positions. Cable sizes are not specified in this manual. The installer must assess the requirements of each site with regard to the regulations and the relevant codes of practice. Before making the connections set all power switches, isolators and circuit breakers to OFF. Remove the battery fuse. The incoming cables must be secured by means of a strain relief glands to the gland plate where they enter the cubicle. The gland plate is not pierced so a suitable hole will have to the cut for each cable entry. The gland plate must be removed from the equipment and taken elsewhere to be drilled to prevent swarf entering the unit. The wires are then to be routed to their respective terminals ensuring that there is enough slack to prevent strain on the terminal. Cable runs should be cleated at intervals of 1/2 metre to rigid structure inside the cubicle. 4.5. TERMINAL CONNECTIONS

4.5.1. Phase rotation The equipment requires the phase rotation to be correct for correct operation. Terminals are labelled for that purpose. 4.5.2. Battery The battery cable should be connected with the battery fuse removed and the battery isolator OFF. Check and double check that the polarity of the battery connection is correct. An error here can cause major damage to the system. WARNING:

DO NOT CLOSE BATTERY ISOLATOR OR FIT FUSES UNTIL THE FILTER CAPACITORS HAVE BEEN PRECHARGED BY THE CHARGER.

4.5.3. Neutral Within the UPS if no neutral-to-earth link is provided the UPS neutral adopts the same potential as the incoming Reserve Neutral. Therefore if the Reserve input has no fixed neutral the UPS output Phase and Neutral will float. Note:

Do not set up a neutral line that has two separate connections to earth because this will set up an EARTH LOOP which can have the effect of introducing noise into the UPS output.

4.5.4. Earth The cubicle earth bar must be grounded to a suitable earth point. Apart from the mandatory safety protection it provides, it also acts as a drain for spurious noise. Consequently there is a continuous leakage to earth of several tens of mA in normal

Page 25 of 65


operation. Therefore Earth Leakage Trips (ELT) or RCCD on the input should take into account this small leakage. 4.6. VENTILATION

All ventilation apertures must be kept free and clean. These systems can work in a continuous environment within 0 to 40°C temperature range, although, ideally the ambient temperature should be below 25°C. The heat can be removed from the equipment room by a forced cooling ventilation system or, alternatively, an air conditioning system. The required air changes per hour will depend on the system rating, the heat loss and the cooling air temperature. 4.7. BATTERY-VENTED LEA D ACID

The battery is a vented lead acid type. It gives off significant amounts of gas (hydrogen and oxygen). A specially ventilated battery room is required. The battery needs its electrolyte topped up routinely. However the battery is suitable for boost charging. 4.8. BATTERY INSTALL ATION

WARNING

REMOVE RINGS AND METAL WATCHSTRAPS WHEN WORKING ON BATTERIES. ALSO USE INSULATED TOOLS.

It is the responsibility of the installer to arrange suitable protection. The installer will have to connect the inter-cell cables as shown in the battery diagram in section 10 of this manual. Before starting, remove the battery fuses and ensure the battery breaker or isolator is OFF. BATTERY INSTALLATION CHECK LIST Battery isolator OFF Battery fuse removed Batteries on each group interconnected. Voltage check of each battery group Check no short from battery to earth Check metal battery cubicles (or metal stands) are earthed Interconnect the battery in accordance with Battery Diagram. Use voltmeter to check the voltage of each half of the battery. Terminate the cables linking the battery and the UPS. Make absolutely sure these are the correct polarity, as an error will cause substantial damage when the equipment is started up.

Page 26 of 65


CAUTION:

DO NOT CONNECT BATTERY POWER TO THE UPS UNTIL THE RECTIFIER SOFT START HAS BEEN ALLOWED TO PRECHARGE THE SMOOTHING CAPACITORS SEE SECTION 5 FIRST START UP.

Check the ambient temperature and once the system is running measure the temperature in the battery cubicle. The batteries are intended for use at 20°C. High temperatures shorten their life. Once the system is running check the charge voltage in: − Float mode − Charge mode − Boost mode.

Page 27 of 65


5. OPERATING INSTRUCTIONS

Title

Page

5.1. LIGHT EMITTING DIODES (LEDS)

29

5.2. DISPLAY

30

5.3. CONTROL PUSH-BUTTONS

31

5.4. PRESENTATION OF THE MENUS

32

5.5. GENERAL MENU

32

5.6. UPS BLOCK MENUS

33

5.7. CONTROL PANEL MENUS

36


42

5.9. MEASURES, FAULTS AND WARNINGS

43

5.10. HEADING

43


46

5.11.1. FIRST START-UP

46

5.11.2. MAINTENANCE PROCEDURE

47

5.11.3. TRANSFER TO MAINTENANCE FOR A STAND-ALONE INVERTER

49

5.11.4. RETURN FROM MAINTENANCE FOR A STAND-ALONE INVERTER

49

5.11.5. GLOBAL MAINTENANCE PROCEDURE

50

5.11.6. BLACK START PROCEDURE

50

Page 28 of 65


The UPS incorporates the necessary controls, instruments and indicators to allow the operator to monitor the system status and performance and take any appropriate action. Furthermore, interfaces are available, which allow extended monitoring and control, as well as service functions. 5.1. LIGHT EMITTING DIODES (LEDS) The UPS has three Light Emitting Diodes (LEDs) to indicate the overall system operation status as well as the condition of the sub-assemblies. These LEDs interact with the active mimic diagram displayed on the graphical display.

Led view

Led colour

Description

Comments

Green

UPS normal operation

AC load supplied by the inverter and the charger is running

Green flashing

load on reserve, or inverter running on battery

Load powered by reserve or inverter running on battery

Orange

UPS warning

One or more subassemblies are affected but UPS not stopped

Red

UPS fault

One or more subassemblies are faulty and stopped or manually stopped.

Red flashing

CAN communication fault

The UPS communication CAN BUS is not correctly plugged or in failure.

STO

The three LEDs are functioning in a permanent way. It is not compulsory to be on the mimic diagram part of the display to activate the operation of the LEDs. The LEDs are functioning independently the ones from the others and they c an be lit simultaneously in some circumstances.

Page 29 of 65


5.2. DISPLAY A graphical (64 x 128 pixels) illuminated Liquid Crystal Display (LCD) is provided to enable the operating parameters, all the measurements and the active mimic diagram of the UPS to be monitored. The LCD messages are accessed by push-buttons (see figure below). The text is available in English, French, Spanish or German or Italian. This local human-machine interface is composed of: 1 A graphical (64 x 128 pixels) illuminated Liquid Crystal Display (LCD). 2 Three LEDs indicating global system functioning and subassemblies functioning. 3 Four push-buttons to access different menus and showed measures. 4 Two push-buttons to power ON / OFF the equipment. 5 One push-button to cut the audible alarm.

1

3

2

5

4

The display has two operating modes: 1. Visualization of an active mimic diagram which gives a graphic representation of the UPS status. 2. Navigation through various menus for visualization of status or measurements information or possible actions on the UPS.

Page 30 of 65


User push-buttons used to control the Graphical Liquid Crystal Display: Select previous Up in menus. Select next Down in menus. Validate parameters Enter in menus.

OK

Cancel parameters Back in menus.

C

User push-button used to control the alarm buzzer: Cancel audible alarm It cancels internal audible alarm until a new alarm occurs.

5.3. CONTROL PUSH-BUTTONS In the right part of the display there are two further push-buttons to control the UPS:

0

0

1

1

Inverter

Starts / Stops rectifier/charger operation: The control incorporates a safety feature to prevent inadvertent operation yet still allow rapid shutdown in the event of an emergency. This shall be achieved by pressing the button for 2 seconds before the charger stops. “SWITCH OFF CHARGER” message is temporarily displayed on the LCD and an OFF pictogram appears on the charger block. To start the charger, it is necessary to push this same button for 1 second: “SWITCH ON CHARGER” message is temporarily displayed and the OFF pictogram on the charger block disappears. Starts / Stops inverter operation : The control incorporates a safety feature to prevent inadvertent operation yet still allow rapid shutdown in the event of an emergency. This shall be achieved by pressing the “STOP” button for 2 seconds before the inverter stops. “SWITCH OFF INVERTER” message is temporarily displayed on the LCD and an OFF pictogram appears on the inverter block. To start the inverter, it is necessary to push this same button for 1 second. “SWITCH ON INVERTER” message is temporarily displayed on the LCD and the OFF pictogram on the inverter block disappears.

Page 31 of 65


REMARK:

The START / STOP push-buttons are permanently active. The action is valid when an ON or OFF message appears on the display. Then graphical display shows the mimic diagram to confirm the new UPS status. The LCD mimic diagram enables to understand the actual status of both charger and inverter to immediately know if both blocks were OFF or ON before pushing the control buttons.

5.4. PRESENTATION OF THE MENUS The information available on the display is of t wo types: mimic diagram or menu. The UPS is structured in "blocks". The organization of the information in the menus is the reflection of this structure. You will find in the General Menu all the UPS blocks as well as some controls. Examples of menus: MENU Charger Battery Inverter Reserve AC Load

CHARGER Status Changing Mode Measurements Faults Warnings

General menu

CHARGER MEASURES UDC IDC U12 U23 U31 I1

= = = = = =

220.1 60.0 241.2 242.0 241.0 70.0

V Amp V V V Amp

Charger menu Charger measures (three-phase UPS) 5.5. GENERAL MENU The general menu allows access to the following sub-menus: Sub-menus for the five UPS blocks: 

Charger



Battery



Inverter



Reserve



AC Load

Sub-menus for the controls: 

Reset



Black Start (Optional)



Event log



Display Setting



Time/Date



Contact



About

Page 32 of 65


To navigate in the menus, use the push-buttons: to come back to the previous item to move to the next item OK

to validate the chosen item and access to the sub-menu corresponding to this item.

NOTES: 

The menus and sub-menus are circular roll down menus.



The selected item is indicated by an arrow ( 4) at the beginning of the line.

5.6. UPS BLOCK MENUS 1. CHARGER MENU Charger Battery Inverter Reserve AC Load

This module allows entry to the following menus: CHARGER Status Changing Mode Measurements Faults Warnings



Charger status menu (to display the charger operational status).



Change charger mode menu (used to change the battery charge mode). See Change charger mode chapter for more details.



Charger measurements menu (for a list of measurements on the charger). See Measures and Faults chapter for more details.



Charger faults menu (for a list of active faults on the charger).



Charger warnings menu (for a list of active warnings on the charger).

Page 33 of 65


2. BATTERY MENU Charger Battery Inverter Reserve AC Load

This module allows entry to the following menus: BATTERY Status Measurements Faults Warnings



Battery status menu (to display the battery operational status).



Battery measurements menu (for a list of measurements on the battery).



Battery faults menu (for a list of active faults on the battery).



Battery warnings menu (for a list of active warnings on the battery).

3. INVERTER MENU Charger Battery Inverter Reserve AC Load

This module allows entry to the following menus: INVERTER Status Measurements Faults Warnings



Inverter status menu (to display the inverter operational status).



Inverter measurements menu (for a list of measurements on the inverter).



Inverter faults menu (for a list of active faults on the inverter).



Inverter warnings menu (for a list of active warnings on the inverter).

Page 34 of 65


4. RESERVE SUPPLY MENU Charger Battery Inverter Reserve AC Load

This module is displayed only if a reserve supply network is confirmed on the customer’s technical specification. This module allows entry to the following menus: RESERVE Status Measurements Faults Warnings



Reserve supply status menu (to display the reserve supply operational status)



Reserve supply measurements menu (for a list of measurements on the reserve supply)



Reserve supply faults menu (for a list of active faults on the reserve supply)



Reserve supply warnings menu (for a list of active warnings on the reserve supply)

5. AC LOAD MENU Charger Battery Inverter Reserve AC Load

This module allows entry to the following menus: AC LOAD Status Measurements Faults Warnings



AC load status menu (to display the AC load operational status)



AC load measurements menu (displays the list of measurements on the AC load)



AC load faults menu (for a list of active faults on the AC load)



AC load warnings menu (for a list of active warnings on the AC load)

Page 35 of 65


5.7. CONTROL PANEL MENUS 1. RESET MENU Inverter Reserve AC Load Reset Black Start

This module allows entry to the following menus: RESET Charger Reset Inverter Reset Event Log Reset Autonom Calcul Rst



RESET charger menu (to erase the memorized charger defaults)



RESET inverter menu (to erase the memorized inverter and static switch defaults)



RESET Log event menu



RESET Autonom Calcul Rst menu (to get the initial

value of Battery Capacity used for the calculation of the battery autonomy

To validate charger or inverter or Event log RESET, click on OK

of the RESET to erase. The display will automatically

go back to the general menu. To erase the charger and inverter blocks stored defaults, repeat the previous operation for both parts.

Page 36 of 65


2. BLACK START (OPTIONAL) MENU Inverter Reserve AC Load Reset Black Start

This module is only available on parallel inverters. It allows entry to the following menu: BLACK START Start the Inverter without Reserve? NO YES

This menu gives the possibility to start parallel inverters, if the Reserve Supply is not present: 

Start both inverters by the control push buttons on each display: the inverters will not yet start, as the Reserve Supply is not present.



Select the Black Start menu on one of both inverters.



Select “YES” with the Down push-button and click on to validate. OK



Both inverters will start simultaneously.

Page 37 of 65


3. EVENT LOG MENU Reserve AC Load Reset Black Start Event Log

This module allows displaying one by one all the events memorised into the historical record, in a chronological order. Example of event: EVENT N° 1 Inverter Fault υHigh DC voltage Memorised Initiated: 17 fev 05 06:18:37

To access the Event Log, select the item Event Log in the general menu of the equipment. The first event of the list is then displayed. If no event has occurred yet, the message « No event » is displayed. Every event is detailed as follows: 

The concerned block,



The text of the detected fault or alarm,



The nature of the event (indicates if the event appeared or disappeared)



The date and time when the event occurred.

The scheduling and the memorizing of the events depend on the choice of the event mode memorizing in the Event Log: Saturable Mode: The first memorised event corresponds to the first fault or alarms that occurred on the equipment, after a UPS power on, or after a Even Log reset. The Event Log is limited up to 100 events and any more events past this limit are memorized. The classification of the events never changes. N°1 : the first event which has occurred (oldest). N°100: the 100th event. FIFO Mode: The first event corresponds to the fault or warning memorized occurred most recently. Once the limit of 100 events memorized in the Event log, if a new event occurs, the oldest event of the Event log will be removed and event which has just occurred will be memorized. The classification of the events always corresponds to the order of which has occurred of the events. N°1 : the most recent N°100: oldest. (if 100 recorded events).

See chapter 4 Display Setting for the selection of the Event Log Mode.

Page 38 of 65


4. DISPLAY SETTING MENU AC Load Reset Black Start Event Log Display Setting

This module allows entry to the following menus: DISPLAY SETTING Serial link Language Event Log Mode Adjust Date/Time



Serial link menu (to direct the serial link of the display board)



Language language.



Event Log Mode menu (to chose between the to mode of Event Log memorizing.



Adjust Date/Time menu (to adjust the date and the time of the system)

menu (to read information in different

Select with Up and Down push-buttons the option requested: to validate, click on

O K . You will then enter the item chosen.

SERIAL LINK: This module allows entry to the following menus indicating the two possibilities. SERIAL LINK Internal External Selected Link: Internal



Internal menu (to direct the serial link to SUB D9 (SK8) of the display board)



External menu (to direct the serial link to RJ 45 (SK6) of the display board)

Select with Up and Down push-buttons the serial link requested: to validate, click on

OK

. You will then enter the

new serial link chosen. LANGUAGE: This module allows entry to the following menus: LANGUAGE English French Spanish German Italian



English menu (to read information in English).



French menu (to read information in French).



Spanish menu (to read information in Spanish).



German menu (to read information in German).



Italian menu (to read information in Italian). OK

To validate the language, click on corresponding to your choice using arrows to go up and down. The display will then return to the general menu.

Page 39 of 65


EVENT LOG MODE: This module allows entry to the following menus indicating the two

possibilities. EVENT LOG Saturable Mode FIFO Mode Actual Setting: FIFO Mode



Saturable Mode (allow to memorize the first 100 events)



FIFO Mode (allow to memorize permanently until the last 100 events )

Select with Up and Down push-buttons the mode requested: to validate, click on O K

. You will then enter the new mode

chosen. It is advised to make a Reset of Event Log after having changed mode. DATE / TIME: This module allows entry to the following menus:

1. Use the keys and to choose the right menu. Choose the "Adjust param" menu and validate with key. OK

ADJUST TIME Adjust Adjust Adjust Adjust Adjust

Year Month Day Hour Minute

2. Setting the parameter:

Use Press

and to set parameter value. key to validate or C to Cancel. OK ADJUST DATE/TIME Adjust Year New value Actual system value

3. If needed, adjust other parameter: Take again items 1 and 2 for the other parameters.

Page 40 of 65


4. Confirm the new adjustments In the menu "Adjust param" press the C key. If at least a parameter was modified, then the following menu appears:

SAVE MODIF ? NO YES

Choose "YES" to safeguard the modifications or "No" pour escape. Press O K to validate your choice. Leaving this window date and time settings appear in the window DATE / TIME.

5. DATE / TIME This module allows access to the actual date and time of the equipment.

6. CONTACT This module allows access to CHLORIDE contact information.

7. ABOUT This module allows access to the equipment information (serial number, issue…).

NOTE: The Contact and About sub-menus are not circular roll menus but only roll down menus.

Page 41 of 65



CHARGER Status Changing Mode Measurements Faults Warnings

CHANGING MODE Request Action No Request Charger Status Floating

CHANGING MODE R e q u e s t A c t i o nτ No Request Floating Equalisation Boost Battery Test

In the Charger menu, click the sub-menu: 

Request action



Charger status

OK

on Changing Mode to enter

OK

Click on Request Action to enter sub-menu: Request Action No request Floating Equalisation Boost Battery test     

OK

Select the needed mode and click . The display will go back to the previous menu to display the required action and also if the charger has really changed the mode. C Click to come back to previous menus. Nota: access to certain modes is not always possible depending on battery types.

Page 42 of 65


5.9. MEASURES, FAULTS AND WARNINGS Each sub-menu Measures, Faults and Warnings are circular roll down menus which can be scanned with arrows : To select previous item To select next item For Faults and Warnings menus, if no fault or warning is present, you can read a label saying “No fault” or “No warning”.

For detailed information, please refer to General Arrangement Drawings and to chapter “ Fault & Diagnosis”.

5.10. HEADING The heading displays the active mimic diagram of the UPS system (see figures below). By pressing the

or

or

buttons, the user can enter the general menu. While navigating in the

menus, the user can return to the active mimic diagram by pressing the necessary.

button as many times as

NOTE: If the user does not request any action (such as pressing a button) for 5 minutes while displaying the menus, the system will automatically return to the display of the heading active mimic diagram.

Active mimic panel (single phase output UPS)

Active mimic panel (Three-phase output UPS)

The active mimic diagram displays the following information: 

Graphical view of the connected load,



Graphical view and percentage of the battery charge level,



Graphical view of the power flow,



Graphical view of the status of each subassembly.

Page 43 of 65


Below are two examples of active mimic situations: Mains input failure Charger stopped AC load still supplied Battery discharging

Active mimic panel (three-phase)

UPS running AC load supplied Inverter not synchronised on reserve

Active mimic panel (three-phase)

The display shows the following information: 1

Charger status

6

Reserve input status

2

Battery status

7

Bypass switch status

3

Inverter status

8

Synchronization status

4

Static switch status

9

Battery current status

5

AC load status

10

Output current status 7

8

6

5

1

9 10

2

3

4

Page 44 of 65


Pictograms list: Charger block

Charger ON and OK Charger ON but with warnings ON Charger stopped following faults detection Charger voluntary OFF Communication problem with the charger Battery block

Battery OK Battery warnings detection Battery faults detection Communication problem with the battery Add to battery pictograms – battery status: Battery in charge Battery in discharge Inverter block

Inverter ON and OK Inverter ON but with warnings ON Inverter stopped following faults detection Inverter voluntary OFF Inverter waiting for start (only in parallel inverter case) Inverter waiting for stop (only in parallel inverter case) Communication problem with the inverter Static switch block

Static switch in ITL position (inverter

AC load)

∧

Static switch in RTL position (reserve supply

AC load)

∧

Static switch in IRTL position (inverter + reserve supply ∧ AC load transitional status) Static switch in open position (AC load is not powered with the switch) Static switch ON but with warnings ON Static switch OFF following faults detection Communication problem with the static switch

.... __

cut off flow continuous flow

Page 45 of 65


NOTE 1:

Pictogram voluntary OFF has priority on Pictogram has priority on .

and

.

NOTE 2:

When pictogram appears on inverter block, it means that the inverter is not synchronized with the reserve supply.


5.11.1. FIRST START-UP Starting situation: All switches, breakers and isolators are open, except both Q21 which are in ‘MAINTENANCE’ position. 

Check the voltage and frequency of the Reserve.



Switch on both Reserve input isolators Q31.



On both UPSs, switch charger primary supply ON. Close charger AC input isolators Q3. Wait 30 seconds for initialisation of the chargers.



Turn both chargers on (Push Charger ON/OFF button “0/1 Charger” for 1 second until “SWITCH ON CHARGER” is displayed on the display). If the text reads “SWITCH OFF CHARGER”, this means the charger was already running: in this case, please push the button again to restart the charger.



Using a hand-held voltmeter, check amplitude and polarity of the charger output voltage, on both chargers.



Also check amplitude and polarity of the battery voltage, on both batteries.



If all previous voltages are correct in amplitude and polarity, close both battery isolators Q5.



Wait until both displays are correctly powered (no more question mark).



Operate an inverter reset on each inverter by the control push buttons (“Reset” part of the LCD General Menu).



On both inverters, close Q24.



On both inverters, turn Q21 to ‘TEST’. After 10 seconds, both Reserve Static Switches will be closed (visible on the synoptic diagram of the Displays).



Using a hand-held voltmeter, check that Output Distribution is correctly powered.



On each display, check the correct display of the DC voltage (Inverter Measurement Menu) and of the AC output voltage (AC Load Measurement Menu).



If you want to check the load transfers, proceed as follows:

Page 46 of 65


 Turn both inverters on by the control push buttons (Push Inverter ON/OFF button

“0/1 Inverter” for 1 second, until “SWITCH ON INVERTER” is displayed on the display): The inverters will not yet start.  Press S22 of INVERTER 1: INVERTER 1 will start and the Static Switch will transfer

from Reserve to INVERTER 1.  Release

S22 of INVERTER 1: The Static Switch will transfer back from INVERTER 1 to Reserve, and INVERTER 1 will stop.

 Press S22 of INVERTER 2: INVERTER 2 will start and the Static Switch will transfer

from Reserve to INVERTER 2.  Release

S22 of INVERTER 2: The Static Switch will transfer back from INVERTER 2 to Reserve, and INVERTER 2 will stop.

 At the end of this test, even if the inverters are not running, turn both inverters off by

the control push buttons (Push Inverter ON/OFF button “0/1 Inverter” for 1 second, until “SWITCH OFF INVERTER” is displayed on the display). 

On both inverters, turn Q21 to ‘TRANSITION’ and ‘AUTO’.



Start both inverters by the control push buttons: both inverters will start simultaneously once you start the second inverter.



The inverters are now running in ‘AUTOMATIC’ mode.

5.11.2. MAINTENANCE PROCEDURE Disconnecting one inverter, supposing that the load will be continuously supplied by the other inverter (This is only possible if the total load is sure never to exceed the nominal power of one inverter).

In this procedure, the inverter to be disconnected for Maintenance will be called INVERTER M, and the Remaining inverter will be called INVERTER R. 

Open Q24 of INVERTER M: the load is now supplied by INVERTER R alone.



On the right of INVERTER M, disconnect both SUB-D25 cables, “MC” and “FC” (cables coming from INVERTER R), from the SUB-D25 socket. Plug “MC” into “FC”. (This will cause an Inverter Fault and a Reserve Warning to occur on the display!)



Reset the inverter alarms on INVERTER R: Inverter block and Reserve are getting normal again on the display.



Stop INVERTER M by the control push buttons.



Isolate INVERTER M from the Load: Turn Q21 of INVERTER M to ‘TRANSITION’, ‘TEST’ and ‘MAINTENANCE’.



Isolate INVERTER M from DC side: Stop the charger, open Q3 and open Q5. Wait long enough to let the capacitors discharge themselves: INVERTER M is now isolated, except the cables beyond the switches and breakers, which may remain live.



INVERTER M is now disconnected.



Before any maintenance operation, always make sure that no more voltage is present on any part you will have to touch.

Page 47 of 65


INVERTER R goes on running normally: it can be switched OFF and ON by the control push buttons (if Reserve voltage is present!). It is also possible to do Maintenance operation on INVERTER R, by following the Maintenance procedures “ Maintenance Procedure for a stand-alone inverter ” and “ Return from Maintenance for a stand-alone inverter ” here below. Reconnecting the second inverter (INVERTER M), supposing that the load is supplied by one inverter alone (INVERTER R).

In this procedure, the inverter which was disconnected for maintenance will be called INVERTER M, and the inverter which supplies the load since the beginning will be called INVERTER R. INVERTER R is supposed to supply the load alone, without any Warning or Fault. 

Energise the DC supply to INVERTER M. Wait until the display is correctly powered (no more question mark).



Operate an inverter reset by the control push buttons of INVERTER M.

 

Turn Q21 of INVERTER M to ‘TEST’. After 10 seconds, the Reserve Static Switch will be closed (visible on the synoptic diagram of the Display). If you want to check the load transfers of INVERTER M, proceed as follows:  Turn INVERTER M ON by the control push buttons (‘SWITCH ON INVERTER’

message on the display): The inverter will not start.  Press S22 of INVERTER M: The inverter will start and the Static Switch will switch

from Reserve to Inverter.  Release S22: The Static Switch will switch back from Inverter to Reserve, and the

inverter will stop.  At the end of this test, even if the inverter is not running, turn INVERTER M off by

the control push buttons (‘SWITCH OFF INVERTER’ message on the display). 

Turn Q21 of INVERTER M to ‘TRANSITION’ and ‘AUTO’.



On the right of INVERTER M, disconnect SUB-D25 cable “FC” from “MC” (cables coming from INVERTER R) and plug these cables into the SUB-D25 socket (“MC” into “FS” and “FC” into “MS”). This will cause an Inverter Fault and a Reserve Warning to occur on the display, and the Reserve Static Switch of INVERTER M to be opened (visible on the synoptic diagram of the Display).



Operate an inverter reset by the control push buttons on both inverters, in order to clear all Warnings and Faults.



Close Q24 of INVERTER M.



Start INVERTER M: the load will be shared between both inverters.



INVERTER M is now reconnected.

Page 48 of 65


5.11.3. TRANSFER TO MAINTENANCE FOR A STAND-ALONE INVERTER 

Check on the inverter display that the inverter is synchronised with Reserve, and that the Reserve voltage is ok (Message “Synchro ” is not flashing on the synoptic diagram, and Reserve Status = “No Warn; No Fault”). CAUTION:

If the inverter is not synchronised AND is supplying the load, or if the Reserve supply is not ok, do not proceed because the supply of the load could be interrupted.



Stop the inverter: the load will be transferred without a break to Reserve.



Turn Q21 to ‘TRANSITION’, ‘TEST’ and ‘MAINTENANCE’.



Isolate the inverter from DC side: Stop the charger, open Q3 and open Q5.



Wait long enough to let the capacitors discharge themselves: the inverter is now isolated, except the cables beyond the switches and breakers, and the complete Reserve and Bypass cabling (Q21 – L24 – Q24 – …) which may remain live.



Before any maintenance operation, always make sure that no more voltage is present on any part you will have to touch.

5.11.4. RETURN FROM MAINTENANCE FOR A STAND-ALONE INVERTER 

Energise the DC supply. Wait until the display is correctly powered (no more question mark).



Operate an inverter reset by the control push buttons.



Turn Q21 to ‘TEST’. After 10 seconds, the Reserve Static Switch will be closed (visible on the synoptic diagram of the Display).



If you want to check the load transfers, proceed as follows:  Turn the inverter on by the control push buttons (‘SWITCH ON INVERTER’ message

on the display): The inverter will not start.  Press S22: The inverter will start and the Static Switch will transfer from Reserve to

Inverter.  Release S22: The Static Switch will transfer back from Inverter to Reserve, and the

inverter will stop.  At the end of this test, even if the inverter is not running, turn the inverter off by the

control push buttons (‘SWITCH OFF INVERTER’ message on the display). 

Turn Q21 to ‘TRANSITION’ and ‘AUTO’.



Start the inverter by the control push buttons.



The inverter is now running in ‘AUTOMATIC’ mode.

Page 49 of 65


5.11.5. GLOBAL MAINTENANCE PROCEDURE If you want to transfer both inverters simultaneously to Maintenance, in order to isolate both inverters, please refer to the paragraphs “ Maintenance Procedure for a stand-alone inverter ” and “ Return from Maintenance for a stand-alone inverter ” here above. All instructions have to be executed on both inverters.

5.11.6. BLACK START PROCEDURE If you want to start the (parallel) inverters while the Reserve voltage is not present, you have to use the Black Start option, on the front door display: 

Power up the DC supply of the inverters, as described here before.



Wait until both displays are correctly powered (no more question mark).



Operate an inverter reset on each inverter by the control push buttons (“Reset” part of the LCD General Menu).



Start both inverters by the control push buttons on each display: the inverters will not yet start, as the Reserve Supply is not present.



On one of both inverters, on the General Menu of the LCD, choose the option “Black Start”. Select ‘Yes’ and confirm by OK. Both inverters will start simultaneously.



Both inverters are now running in ‘AUTOMATIC’ mode. There is no memorisation of t he Black Start, so you don’t have to reset anything, once the Reserve Supply has come back.

Page 50 of 65


6. ROUTINE MAINTENANCE Title

Page

6.1. GENERAL

51

6.2. ONCE A WEEK

51

6.3. ONCE A MONTH

51

6.4. AT LEAST 4 TIMES PER YEAR

52

6.5. ANNUALL Y

52

6.6. FANS

52

6.1. GENERAL

Under normal operating conditions only preventative maintenance is required. The intervals between maintenance actions will vary according to the level of remote monitoring and the standard of cleanliness of the equipment room. 6.2. ONCE A WEEK

Check all alarm and status indicators. Check meter readings are normal. Compare them with the test certificate. Check the cause of any significant changes. For example, change in load, recent discharge Record all abnormal occurrences in the service log 6.3. ONCE A MONTH

Check ventilation apertures are clean and clear of obstructions On cells check the battery electrolyte levels and top up if necessary in accordance with the manufacturers instructions.

Page 51 of 65


6.4. AT LEA ST 4 TIMES PER YEAR

Check ventilation grilles Visually check electrical connections and component for signs of overheating or corrosion. Rectify as necessary. Check painted and plated components for signs of damage or corrosion. Rectify as necessary 6.5. ANNUALLY

Carry out a test discharge of the battery for the specified autonomy. Note:

The test should be carried out at a time of low risk and followed immediately by a full recharge. Consult the battery manufacturer's instructions for guidance on frequency of testing, depth of discharge etc.

6.6. FANS

Fans are rated for a 5-year life. It is recommended that fan failures be pre-empted by renewing them after four years.

Page 52 of 65


7. FAULT DIAGNOSIS Title

Page

7.1. CHARGER DISPLAY MENU

54


55


56


56

7.5. BATTERY FAULT

57

7.6. BATTERY WARNING

57


58


59

7.9. INVERTER VOLUNTARY STOPPED

60


60

7.11. RESERVE WARNING

61

7.12. AC LOAD/ STATIC SWITCH FAULT

61

7.13. AC LOAD/STATIC SWITCH WARNING

62

Your requests can be sent at: [email protected] This mailbox address is checked permanently during working days and office hours of the factory.

Page 53 of 65


7.1. CHARGER DISPLA Y MENU

Charger fault is designed by pictogram.

on the charger

Select Charger in the general menu and click on OK

to valid.

In order to have access to the Faults menu, select Faults in the Charger menu and click on valid.

OK

to

In this menu all faults appear (instantaneous and memorized faults)

If no faults are shown on the display then No faults appears in this menu.

Click twice on Cancel to come back to the general menu.

Page 54 of 65



CHARGER FAULTS

POSSIBLE CAUSES

SOLUTIONS

AC Supply fault

Loss of AC supply, lack of one phase, too high or too low amplitude, wrong phase sequence for three phase charger

Wrong phase sequence

On three phase charger, the phase sequence is not correct Amplitudes of one or several phases are not OK

Check fault nature on the LCD display (amplitude or phase problem). Check input supplies. If AC supply is OK on power input terminals, check auxiliary fuses on internal electronic door (F10) Interchange two phases, to reverse direction of phase rotation Check input supply on power input terminals. If AC supply is OK on power input terminals, check auxiliary fuses on internal electronic door (F10) Check all the wires connected to the INCA circuit board. If the wiring is correct, the problem can be linked with card problem: Call engineer.

AC voltage NOK

High DC Voltage

High DC Voltage Memorized

Too high I battery Memorised

Charger fuse blown

Input protection opened

Loss of charger voltage regulation in case of charger alone configuration (The fault is not memorized and the charger runs intermittently in order to continue to supply the DC load). Loss of charger voltage Check all the wires connected to regulation in case of parallel the INCA circuit board. If the configuration charger (The fault wiring is correct, the problem can is memorized and the charger is be linked with card problem: Call cut) . The DC load is supplied engineer. by the redundant charger(s) Reset this memorized fault with the LCD display charger reset. Loss of battery current Check all the wires connected to regulation. the INCA board and the battery current Hall effect sensor. If the wiring is correct, the problem can be linked with card or sensor problem: Call engineer. Reset this memorized fault with the LCD display charger reset. Charger bridge high speed fuse Check loading, thyristors, renew blown due to sudden short fuse, rearm the microswitch circuit on the DC side or detector. In case of a new problem on charger control occurrence, check the control loop. wiring on the INCA board. The problem can be linked with a board: Call engineer. Input protection tripped or Check loading and possible short opened. circuit or overload on the DC side. Rearm the protection.

Page 55 of 65


Remote emergency stop

Optional remote charger switch is acting. (Optional switch) (or redundant high DC voltage monitor is acting).

Check if the charger is not cut by an external remote switch. (Check if the redundant voltmetric relay is not acting on the INCA board by looking at red LED10)

3 other charger fault specific messages can be detected in this part due to equipment customisation. Check these messages in the General Arrangement drawing (PA)


Charger switch Off

The charger is cut from the CANDIS board.

Give an ON charger order with CANDIS push button.


CHARGER WARNING

POSSIBLE CAUSES

SOLUTIONS

Fan failure

One charger bridge fan is not supplied or blocked (in case of forced air cooling charger bridge) The charger DC voltage is not yet in voltage level regulation: Overload on the DC side, or battery is charging in current limitation after a discharge, or possible problem of voltage regulation due to a too low AC mains level.

Remove the charger AC and DC power supply, and isolate it. Replace the fan in failure.

DC voltage low

Test mode

The charger is in special production or commissioning mode.

Check if the DC load is not too high or if the charger is in battery current limitation, by looking at IDC or Ibatt current level on the display board. If both preceeding points are not satisfied, check if the AC mains amplitude is not too low before to call engineer. Call engineer

3 other charger warning specific messages can be detected in this part due to equipment customisation. Check these messages in the General Arrangement drawing (PA)

Page 56 of 65


7.5. BATTERY FAULT

BATTERY FAULTS

POSSIBLE CAUSES

SOLUTIONS

Battery Test Fault Memorized

Following an automatic or a manual battery test, a battery fault has been detected due a too rapid discharge rate.

End of discharge

Low DC trip level has been passed.

Battery protection opened

Battery fuse or circuit breaker open.

Check battery connections. Check battery not damaged. Call engineer. Reset this memorized fault with the LCD display charger reset. If AC supply fail, no action. Check no charger fault. Call engineer. Check DC loading then reconnect.

3 other battery fault specific messages can be detected in this part due to equipment customisation. Check these optional messages in the General Arrangement drawing (PA) 7.6. BA TTERY WARNING WARNING

BATTERY WARNINGS

POSSIBLE CAUSES

DC Earth fault

Current leakage between battery and earth or DC polarities and earth.

Battery begin of discharge

Imminent shutdown

Temp sensor fault memorized

BMS Battery Cell warning BMS Hardware Fault

SOLUTIONS

Danger, DO NOT CARRY OUT BATTERY MAINTENANCE .Check battery cable insulation. Check battery cell insulation. Try to isolate the failed part by switching DC load or battery off. Call engineer. AC supply fail. If AC supply fail, no action. Check no charger fault. Call engineer. AC supply fail. If AC supply fail, no action. Battery voltage is low. Indicates Check no charger fault. battery discharged close to trip level. Call engineer The battery temperature sensor used to Check the connection of battery achieve the battery voltage temperature sensor. compensation control is in failure and Reset this memorized fault with the the charger runs with a temperature LCD display charger reset. default value of 20°C. If new occurrence, call engineer. See BMS User Manual See BMS User Manual

3 other battery warning specific messages can be detected in this part due to equipment customisation. Check these messages in the General Arrangement drawing (PA).

Page 57 of 65



Inverter fault is designed by pictogram.

on the inverter

Select Inverter in the general menu and click on OK

to valid.

In order to have access to the Faults menu, select Faults in the Inverter menu and click on valid.

OK

to

In this menu all faults appear (instantaneous and memorized faults)

If no faults are shown on the display then No faults appears in this menu.

Click twice on Cancel to come back to the general menu.

Page 58 of 65



INVERTER FAULTS

POSSIBLE CAUSES

VCE Fault M.

Inverter bridge transistor desaturation detected due to an excessive current. Inverter is stopped.

Inv. Overld Flt M.

Overtemp. Flt M.

Low DC voltage.

Repeated Low DC M.

High DC voltage M.

High AC voltage M.

SOLUTIONS

Check the AC load. Reset this memorized fault with the LCD display inverter reset. If new occurrence, call engineer (inverter bridge or driver problem). Inverter is stopped due to a too long Reduce load. overload time or repetitive transfer Reset this memorized fault on reserve. with the LCD display inverter reset. An overtemperature is detected on Check the air input/output the inverter bridge due to a problem cleanness and the fan running. After correction, of cooling (possible fan failure or air input /output blocked ). reset this memorized fault with the LCD display inverter reset. If new occurrence, call engineer. The inverter is stopped due to a low Check why the DC voltage DC voltage input. inverter input is too low. (Charger running or battery exhausted). The inverter is stopped as result of Check why the DC voltage repetitive low DC voltage inverter input is too low. detection. (Charger running or battery exhausted). Reset this memorized fault with the LCD display inverter reset. Inverter is stopped due to a too high Check the charger DC DC voltage input caused by a voltage. After correction, charger problem. A possible cause reset this memorized fault can be also linked with a bad static with the LCD display switch running. inverter reset. If new occurrence, call engineer. Inverter output regulation problem. Check the wiring of the inverter LION interface board. After correction, reset this memorized fault with the LCD display inverter reset. If new occurrence, call engineer.

Page 59 of 65


Frequency Fault M.

Inverter output regulation problem.

Paral. Com. Flt M.

Problem detected in the communication between the different parallel running units (in case of inverter parallel running) Inverter running stopped by a microcontroller fault on the Inverter CUdSMC board.

Microcontroller fault

Check the wiring of the inverter LION interface board. After correction, reset this memorized fault with the LCD display inverter reset. If new occurrence, call engineer. Check correct insertion and wiring of optional POB board. Reset this memorized fault with the LCD display inverter reset. If new occurrence, call engineer

3 other inverter fault specific messages can be detected in this part due to equipment customisation. Check these messages in the General Arrangement Drawing (PA). 7.9. INVERTER VOLUNTARY STOPPED

Inv. switched Off

The inverter is cut from the CANDIS board.

Give an ON inverter order with CANDIS push button.


INVERTER WARNINGS

POSSIBLE CAUSES

Redundant fan failure

One inverter bridge fan is not supplied Follow the maintenance inverter or blocked (in case of forced air cooling procedure in order to isolate the inverter bridge) inverter part from an electrical point of view .Replace the fan in failure. The inverter is feeding a too high AC Check the overload reason and load. If this overload is not diminished reduce the load. rapidly the inverter will stopped after a time depending on the overload level. Transient microcontroller problem, Call engineer inverter may still be running. Running mode used for commissioning. Modify the configuration with Operator has forgotten to replace the PPVIS software. inverter in normal operation configuration. Fan used is too old. Check the expected lifetime of the different fans of the equipment, and replace them if required.

Inv. Overload warning

S/W Time-out. Commissioning

Fan Life expired

SOLUTIONS

Page 60 of 65


3 other inverter warning specific messages can be detected in this part due to equipment customisation. Check these messages in General Arrangement Drawing (PA) 7.11. RESERVE WARNING

Remark : For ON LINE INVERTER configuration, a reserve NOK is not considered as a fault but as a warning, because it doesn’t imply a direct loss of the AC load. RESERVE WARNINGS POSSIBLE CAUSES

Reserve Voltage NOK

Res. Frequency NOK

Phase Sequence

Reserve Inhibited Paral. Res. Flt M.

SOLUTIONS

The reserve voltage is not correct or the Check the reserve amplitude, try reserve is absent. to establish a correct reserve. No action on the inverter. The reserve frequency is not correct Check the reserve frequency, try to establish a correct reserve. No action on the inverter. For three phase inverter, the phase Interchange two phases, to sequence is not correct. reverse direction of phase rotation Error of software configuration. Call engineer. In case of “paral. Com. Flt M.” active, Check the displayed reserve refer to comments of this fault. In the voltage and frequency, and other case, there is a problem on one of reserve warning messages on the parallel reserve supplies. each UPS.

3 other reserve warning specific messages can be detected in this part due to equipment customisation. Check these messages in the General Arrangement Drawing 7.12. A C LOA D/ STATIC SWITCH FAULT

AC LOAD/ STATIC SWITCH FAULTS

POSSIBLE CAUSES

SOLUTIONS

Emerg. Power Off

The AC load is no more supplied due to an Emergency power Off order sent to the dedicated input. The reserve static switch has fed a too high AC load for a too long time.

Check the reason of the volunteer Emergency Power Off order. Reduce load. Reset this memorized fault with the LCD display inverter reset. Check the wiring of the inverter static switch and its associated driver (both anti parallel SCRs must be driven so as to have positive and negative voltage on the AC load). After correction, reset this memorized fault with

S.S Overload Flt M.

Inv. Stat Sw Flt M.

The inverter static switch is in failure and is not correctly controlled.

Page 61 of 65


Res stat Sw Flt M.

The reserve static switch is in failure and is not correctly controlled.

Stat Sw H/W Flt M.

Problem in the power supply of the reserve static switch driver board.

the LCD display inverter reset. If new occurrence, call engineer. Check the wiring of the reserve static switch and its associated driver (both anti parallel SCRs must be driven so as to have positive and negative voltage on the AC load). After correction, reset this memorized fault with the LCD display inverter reset. If new occurrence, call engineer. Check the power supply of the COGAS or CDCS boards.

3 other AC LOAD/ Static Switch fault specific messages can be detected in this part due to equipment customisation. Check these messages in the General Arrangement Drawing (PA) 7.13. A C L OAD/STATIC SWITCH WARNING

AC LOAD/ST.SW WARNINGS

POSSIBLE CAUSES

AC Earth Fault

An AC earth Fault has been detected on In case of several AC loads, try the AC load part (Option). to define which load is in failure by cutting the supply of the different load. The AC load is supplied by the reserve After Maintenance operation, with the Manual bypass for don’t forget to come back in maintenance purpose. automatic configuration in order to have the maximum autonomy and reliability. The reserve static switch is feeding a Check the overload reason, and too high AC load. If this overload is not reduce the load. diminished rapidly, the reserve static switch will be shut off.

Manual Bypass On

S.S. Overld Warn.

SOLUTIONS

3 other AC LOAD/ STATIC SWITCH warning specific messages can be detected in this part due to equipment customisation. Check these messages in the General Arrangement Drawing (PA)

Page 62 of 65


8. SPARE PARTS Titre

Page

8.1. GENERAL NOTES

63

8.1. GENERAL NOTES

To maintain the high level of performance and reliability of these secure power systems the following rules are applied: − − − −

Careful choice of components Manufacturing according to recognised standards and codes of practice Strict quality control Careful adjustment and regulation.

However, in use, problems can occur which require parts to be replaced or repaired. Replacement of defective parts can sometimes be made by the user to restore correct operation of the system which may then be returned to service. For this spare parts will be required. For continued reliability only approved, identical replacement parts may be used. Where necessary these must be adjusted to the original set values. Chloride Industrial Systems After Sales Service Department has records of recommended spares for all equipment. When ordering spare parts it is essential to identify the equipment by quoting the serial number and the design number (RB) stamped on the rating plate.

Page 63 of 65


9. DRAWINGS Title

Page

9.1. GENERAL NOTES

64

9.1. GENERAL NOTES

The drawings included in this manual are current at time of issue but are not necessarily changed at each revision. Check the site master drawing system for the latest issue status. Wire numbering. Internal wiring is identified on a point to point basis. Each wire has an individual number and is identified at both ends unless too short for two markers. All wire numbers and termination points are detailed on the schematic diagrams. Terminal identification. Terminals are identified on the schematic. Drawing identification. The Chloride drawing prefixes identify the type of drawing PA

- General arrangement drawing

PA-320222

SU

- Single line diagram

SU-320222

DT

- Technical file

DT-320222

Circuit card drawings. Detailed circuit drawings are not provided. These represent the proprietary knowledge and experience of Chloride Industrial Systems and are commercially confidential. In addition they do not assist with the understanding, operation and maintenance of the UPS systems. Except in the hands of adequately trained, experienced and qualified personnel we have found that these diagrams are often used t o adjust or modify the systems in ways detrimental to the performance and reliability of the systems. These diagrams will only be supplied to personnel who have successfully completed a Chloride Industrial Systems training course or who have adequately proved to the quality manager of Chloride Industrial Systems that their level of training, experience and qualification is sufficient to enable them to use the information safely. Such issue is on a personal basis and does not authorise 3rd party use.

Page 64 of 65


10. ATTACHMENTS Title

10.1. BATTERY MANUAL

Page

65

10.1. BA TTERY MANUAL

Page 65 of 65

HOPPECKE

Installation instructions for stationary batteries (Batteries / stands / cabinets) Observe the operating instructions! Work on batteries only under instruction of skilled personnel only, obser ving commissioning instructions and instructions for use! When working on batteries wear protective glasses and clothing! Observe the accident prevention rules as well as EN 50272-2, VDE 0105 part 1! Smoking prohibited! Do not expose the battery to open flame, glowing embers or sparks as explosion and fire hazard exists! Acid splashes in the eyes or on the skin must be washed out or off with plenty of water. Then consult a doctor immediately. Clothing contaminated with acid should be washed with water!

1. Requirements and preparations for installation 1.1. Before installation ensure that the bat-

tery room is clean and dry and is furnished with a lockable door. The battery room must be set out and marked with warning marks according to EN 50272-2. Particular attention must be paid to the following: - floor load-carrying capacity and nature (conveying paths and battery room) - electrolyte resistance of battery installation surface - no ignitable sources (e.g. open flame, glowing objects, electric switches) near the cell openings (500 mm ”safety distance”) - ventilation conditions To ensure smooth operation, coordination between other persons working in the same room is necessary.

Explosion and fire hazard, avoid short circuits! Caution! Metal parts of the batteries are always live, do not place tools or other objects on the OPzS cells battery! OPzS bloc batteries max.power cells Electrolyte is strongly corrosive. Under normal operating conditions solar.power cells exposure to electrolyte is impossible. GroE cells Should the casing be destroyed, the OGi cells released fixed electrolyte is as corroOGi bloc batteries sive as liquid electrolyte. OSP cells Block batteries and cells are OSP.HC cells extremely heavy! USV bloc batteries Ensure secure installation! Only use suitable handling OPzV cells equipment, tools and measuring OPzV bloc batteries equipment! power.com SB / power.com HC net.power Dangerous voltage!

1.2. Check deliveries for completeness and

damage. If necessary, clean all parts before assembling. 1.3. Observe all documentation included with the delivery (e.g. battery-, rack-, cabinet-assembly drawings). 1.4. Before renewing old batteries ensure that all electric loads are switched off (separator, fuses, switches). This must be carried out by qualified personnel.

CAUTION: Do not carry out unauthorised switching! 1.5. Open-circuit voltage measurements

of individual cells or block batteries. Ensure correct polarity. With unfilled and charged batteries these measurements can only be carried out after start-up. Fully charged cells have the following listed open circuit voltages at an electrolyte temperature of 20°C:

DIN 40736 P1 DIN 40737 P3 DIN 40736 P2 DIN 40738 DIN 40734 DIN 40739

DIN 40742 DIN 40744

(2.08 ± 0.01) V/C (2.08 ± 0.01) V/C (2.08 ± 0.01) V/C (2.08 ± 0.01) V/C (2.06 ± 0.01) V/C (2.08 ± 0.01) V/C (2.08 ± 0.01) V/C (2.11 ± 0.01) V/C (2.08 ± 0.01) V/C (2.13 ± 0.01) V/C (2.08 - 2.14) V/C (2.08 - 2.14) V/C (2.08 - 2.14) V/C (2.08 - 2.14) V/C

The open-circuit voltages of a battery’s indi vidual cells must not deviate from each other more than 0.02 V. The following maximum open-circuit voltage deviations for block batteries apply: 4 V block batteries 0.03 V/block 6 V block batteries 0.04 V/block 12 V block batteries 0.05 V/block Higher temperatures decrease, lower temperatures increase the open-circuit voltage. With a deviation of 15 K from the nominal temperature the open-circuit voltage changes by 0.01 V/cell. Should greater deviations occur, consult the supplier. 2. Racks 2.1. Align the racks according to the instal-

lation drawing. Should an installation drawing be missing, the following minimum distances must be observed: - To the wall: 100 mm on all sides for the cell or block container, or 50 mm for the rack. - 1.5 metres by a nominal or component voltage > 120 V between non-insulated terminals or connectors and earthed parts (e.g. water pipes) or between the battery’s end terminals. During installation it must be ensured that DIN VDE 0510, Part 2, EN 50272-2 is adhered to (e.g. cover electrically conductive parts with insulating mats). - To ignitable sources: For distance from the nearest cell vent see EN 50272-2. - To passageways: 1.5 x cell width (installation depth) but not less than 50 cm. 2.2. Align racks horizontally using the le-

velling parts or adjustable insulators provided. The distances of the support profiles must correspond with the cell or block battery size. Check rack stability and ensure that all screw and clamp connectors are firmly seated. If stipulated, earth the rack or parts thereof. Protect screw connectors from corrosion. Please note that when using wooden racks a flexible connector must be fitted between each rack joint. 2.3. Check that cells or block batteries are sound (visually, polarity).

HOPPECKE Batterien

2.4. Place each cell or block battery onto

the rack with the correct polarity. With large cells it is recommended that cell installation should commence from the middle of the rack. - Arrange cells or batteries plumb and level with the correct polarity. - Distance between the cells should be approx. 10 mm or according to the length of the connectors supplied. - If necessary clean the contact surface of the terminals and connectors. - With screwed connectors: · Remove protective caps from terminals · Check · that the terminal surfaces are properly greased with neutraliser and protected by means of red or blue terminal cover rings, · that the O-ring or grease groove is completely filled with neutraliser and the O-ring is seated, as specified, on the grease pad, · that the threaded insert is suffici ently full of neutraliser and the terminal contact surface is greased. - Fit cell or block connectors and tighten with an insulated torque wrench (20 Nm  1 Nm). Caution: Screws are approved for single use. - Fit row, step, tier connectors and tighten observing the specified torques. - After fitting, the welded connectors of the individual cells GroE/OGi/OPzS/ OSP.HC/max.power must be aligned and welded to the terminals as specified. Observe the specifications under VBG 15. - If necessary, fit insulating caps onto cell/ block connectors and end terminals. - Ensure short-circuit proof installation work. Wiring with a dielectric strength and a designed operating voltage above the maximum possible battery system voltage must be used, or a distance of approx. 10 mm between wiring and electrically conductive parts must be kept or the connectors must be furnished with additional insulation. Avoid mechanical stress on the cell/ battery terminals. - If applicable, remove transport plugs and replace with sealing plugs. - Check electrolyte level (observe operating instructions/commissioning instructions). - Measure the total voltage which should equal the total open circuit voltages of the individual cells/block batteries. HOPPECKE Batterien GmbH & Co. KG, Brilon P.O.Box 1140 D-59914 Brilon

- If necessary, number the cells or block batteries visibly (from the battery’s positive terminal to the negative terminal). - Affix polarity labels for the battery connectors. - After assembly completion affix nameplate integrated in operating instructions. - Affix safety marking sign and operating instructions visibly. The batteries must not be cleaned with feather dusters or dry cloths, this could cause electrostatic charge (explosion hazard). 3. Cabinets 3.1. Cabinets with built-in battery:

- The battery cabinet is assembled on site (observing the relevant accident prevention rules). - Take into account additional space needed between wall and cabinet for possible or planned cable entries. - Remove any transport safety devices from the built-in cells or block batteries. - Check cells or block batteries for correct position and mechanical damage. 3.2. Cabinets with separately deli vered cells or block batteries:

- Only filled and charged cells or block batteries (vented or sealed) are built into cabinets. - Assemble cabinet, place in designated location and align (observing the relevant accident prevention rules). - Place cells or block batteries into the cabinet according to assembly plan and spacing specified, connect them and mark (see item 2.4). 4. CE marking

Since 01.01.97 an EC declaration of conformity under the low voltage regulation is required for batteries from 75 V to 1500 V nominal voltage with the corresponding CE labelling on the battery. The battery installer of the battery plant is responsible for issuing the declaration and affixing the CE label on or next to the battery’s nameplate. CAUTION! Before connecting to the charger ensure that all assembly work has been duly completed! Phone (029 63) 61-0 · Fax (0 29 63) 61-4 49 http://www.HOPPECKE.de e-Mail: hoppecke.IOt-online.de

y n a m r e G n i d e t n i r P H 1 / 2 0 . 7 0 / 2 0 . 3 0 / 1 9 1 3 0 2 0 4 1 7 . r N l i e T

IOM-320222 Equipment and Battery Information

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