Professional Documents
Culture Documents
Customer:
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
INDIAN OIL CORPORATION LTD
2.2 MTPA DHDT PLANT - VADODARA
REFINERY PROJECT
P.O. FAO 3293/2007 & 3293/2007/18008326
DUAL UPS Apodys 70kVA 400VDC 1x110V
CHLORIDE REF : DT 318107
PROJECT : 080930 / 05
OF : W015939
CHLORIDE
INDUSTRIAL SYSTEMS
LIST OF REVISIONS
ISSUE
DATE
REVISED PAGES
00
07/09/09
First Issue
Page 2 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
LIST OF CONTENTS
Title
Page
1. SAFETY
1.1. GENERAL
1.5. BATTERY
11
14
2.1. DESCRIPTION
14
2.2. TOPOLOGY
14
17
3. SYSTEM SPECIFICATION
22
3.1. CHARACTERISTICS
22
4. INSTALLATION
23
23
4.2. STORAGE
24
24
25
25
25
25
25
25
4.6.2. Battery
25
4.6.3. Neutral
26
4.6.4. Earth
26
Page 3 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
4.7. VENTILATION
26
26
26
5. OPERATING INSTRUCTIONS
28
29
5.2. DISPLAY
30
31
32
32
33
36
41
42
5.10. HEADING
42
45
46
46
47
47
48
48
50
52
52
53
53
6. ROUTINE MAINTENANCE
54
6.1. GENERAL
54
54
54
55
Page 4 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
6.5. ANNUALLY
55
6.6. FANS
55
7. FAULT DIAGNOSIS
56
57
58
59
59
60
60
61
62
63
63
64
64
65
8. SPARE PARTS
66
66
9. DRAWINGS
67
67
10. ATTACHMENTS
68
68
Page 5 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
LIST OF ILLUSTRATIONS
Title
Page
14
15
17
18
18
19
20
21
Page 6 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
1. SAFETY
Title
Page
1.1. GENERAL
1.5. BATTERY
11
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
CAUTION :
WARNING :
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 and supplied with the battery.
Page 7 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Page 8 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Nature of hazard.
The hazards are :
Risk of electric shock
Risk of electric burns
Risk of chemical burns
Risk of poisoning
Page 9 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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
experiences 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 for anyone intending to carry out maintenance work on it.
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 symmetrical voltages with
respect to earth. Any abnormal short, even of high resistance, will disrupt this symmetry.
WARNING
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
difference.
ELECTRIC BURNS
The prospective short circuit current from a battery is very great. So even a modest cell will
deliver over a thousand amps into a short circuit such as a metal watch strap, ring 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
Page 10 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Page 11 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
BATTERY PLATES
The plates will be of Nickel, Oxides of Nickel, Cadmium and Oxides of Cadmium or a
combination of these dependant upon the condition of the battery. The plates may be porous
and impregnated with Potassium Hydroxide.
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.
Page 12 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Page 13 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Page
2.1. DESCRIPTION
14
2.2. TOPOLOGY
14
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
INVERTER 1
STATIC
SWITCH
BATTERY
CHARGER 1
BATTERY
Page 14 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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
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.
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.
Page 15 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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.
Mode 2.
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.
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.
Page 16 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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
INVERTER 1
STATIC
SWITCH
BATTERY
CHARGER 1
BATTERY
Page 17 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
INVERTER 2
STATIC
SWITCH
INVERTER 1
STATIC
SWITCH
BATTERY
CHARGER 1
BATTERY
FLO A T
V O LTA GE
INVERTER
SHUTDOWN
IMMINENT
LO W DC TRIP
Page 18 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
RESERVE-TO-LOAD MODE
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
CHARGER 2
INVERTER 2
STATIC
SWITCH
INVERTER 1
STATIC
SWITCH
BATTERY
CHARGER 1
BATTERY
Page 19 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
INVERTER 2
STATIC
SWITCH
INVERTER 1
STATIC
SWITCH
BATTERY
CHARGER 1
BATTERY
CAUTION:
Page 20 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
INVERTER 2
STATIC
SWITCH
INVERTER 1
STATIC
SWITCH
BATTERY
CHARGER 1
BATTERY
Page 21 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
3. SYSTEM SPECIFICATION
Title
Page
3.1. CHARACTERISTICS
22
3.1. CHARACTERISTICS
CHARGER
Battery
Capacity:
Number of cells
Autonomy
415 V
50 Hz
150 A
413,13 V
483,45 V
498,1 V
209 A
3360 W
triggering: 529 V
KBM310
310 Ah
293
60 min
INVERTER
70 kVA
110 V
50 Hz
636,4 A
415 V
6,2 kW
triggering: 529 V
Page 22 of 68
EQUIPMENT
CHARGER TEST
REPORT
POWER SUPPLY
Item: CH1
N: L09-0831
WO: 15939
RB: 318107
LOAD
V 3 Ph
Hz
Voltage
415
Frequency
50
TAG CUSTOMER :
Battery type :
Ah
310
293
Cells
Vented Ni Cd
PRELIMINARY CHECK
Dielectric
2000 Vac
~ / ground
Equalizing / Floating
Dielectric
2000 Vac
= / ground
Equalizing / Floating
Dielectric
2000 Vac
~/=
Boost time
Insulation
500 Vdc
R > 10 M
Compensation U= f (C)
R < 0,10
V
A
370
209
min
X
N/A
X
62.0
15 H
mV / C / cells
N/A
A equalize / float
Time
Output
Input protection
Internal lightning
DC fuse tripping
Anti-condensation heater
Signalling test
Communication
Pv = 640.0
Losses no load
+ 10
- 10
Nominal U
Nominal U
I DC
CHECKING
Phase equilibrium (3 phases)
Supply
Type : Aucun
CONTROL
Charge
Mode
Type : Modbus
Ufloat =
Regulation
Efficiency
0.42931 %
Ucharge =
V at In/2
413.10
483.50 V at In/2
Uboost =
X
1.0
1.0
95.0
498.10
NOK
Lim. Iboost =
U12
I1
U23
I2
U31
I3
PT
UDC
IDC
P( U x I )
0,1 In 455.0
62 A
PF
Ripple
VRMS
456.0
455.0
485.1 19.3
1.38
In
374.0
375.0
374.0
484.5 206.0
1.30
In
416.0 148.0
417.0
147.0
416.0 147.0
416.0
148.0
415.0 147.0
472.0 209.0
99807
95.88
0.98
2.08
2.18
SUBJECT
External aspect
IEC 529
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
Wiring
Identification
IEC 439
Cleaning
CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts
Tested by :
MMO
CHECKED
CUST.
COMMENTS
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Date : 12/8/2009
Charger Test
Checked by :
LDU Date :
Page
Reference
Index
12/08/09
PGE 18 UK
EQUIPMENT
INVERTER TEST
REPORT
LOAD
Item: INV1
N: L09-0831
WO: 15939
RB: 318107
POWER SUPPLY
V 1 Ph
Hz
kVA
Voltage
110
Frequency
50
Power
70
TAG CLIENT :
2000 Vac
= / ground
Dielectric
2000 Vac
~ / ground
Dielectric
2000 Vac
~/=
Insulation
500 Vdc
R > 10 M
R < 0,10
Ah
310
293
Cells
Vented Ni Cd
Battery type :
OPTIONS
PRELIMINARY CHECK
Dielectric
V
A
370
209
Precharge DC
N/A
N/A
N/A
Output
Internal ligthning
Anti-condensation heater
Communication
Types : Modbus
Aucun
Inverter type
Fan failure
Transfer time
Signalling test
ON LINE
Main->Inv
OFF LINE
Inv->Main
0 ms
U =
0 ms
0.0 V
0.00
3.00 %
10.00%
572.00 V
X
X
NO LOAD TEST
Losses no load
Pv = 2670.0
Voltage no load
US = 110.00
F = 50.00
Hz
Frequency no load
CHECKING
Phase equilibrium (in 3 Ph)
Regulation
I = 574.6
Distortion = 3% at cos = 1
I = 547.3
Efficiency
Short circuit
I = 1190.0
REGULATION
Bridge type :
UDC
IDC
P( U x I )
N/A
1.0
X
X
92.0 %
IFH42S400
U12
U23
U31
I1
I2
A
I3
Ptotale
cos
484.5
19.2
9302.4
109.6
61.3
6718.5
72.2
2.4
Ubatt. High
In
481.7
162.0
78035.4
109.0
639.0
69651.0
89.3
2.8
Ubatt. Low
0,5 In
302.0
128.0
38656.0
109.4
319.6
34964.2
90.4
2.4
Ubatt. Low
In
301.4
256.0
77158.4
109.0
639.0
69651.0
90.3
2.6
SUBJECT
External spect
IEC 529
CHECKED
CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications
X
X
X
X
X
X
- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen
X
X
X
X
X
X
X
Wiring
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
X
X
X
X
X
X
Identification
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
X
X
X
X
X
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
IEC 439
Cleaning
COMMENTS
Comments :
Tested by : MMO
CUST.
X
X
X
X
X
X
X
Inverter test
Checked by :
LDU Date:
Page
Reference
Index
12/08/09
PGE 20 UK
EQUIPMENT
CHARGER TEST
REPORT
POWER SUPPLY
Item: UPS1+A1+CH
N: L08-1262
WO: 16939
RB: 318107
LOAD
V 3 Ph
Hz
Voltage
415
Frequency
50
TAG CUSTOMER :
Battery type :
Ah
310
293
Cells
Vented Ni Cd
PRELIMINARY CHECK
Dielectric
2000 Vac
~ / ground
Equalizing / Floating
Dielectric
2000 Vac
= / ground
Equalizing / Floating
Dielectric
2000 Vac
~/=
Boost time
Insulation
500 Vdc
R > 10 M
Compensation U= f (C)
R < 0,10
V
A
370
209
min
X
N/A
X
62.0
15 H
mV / C / cells
N/A
A equalize / float
Time
Output
Input protection
Internal lightning
DC fuse tripping
Anti-condensation heater
Signalling test
Communication
Pv = 700.0
Losses no load
+ 10
- 10
Nominal U
Nominal U
I DC
CHECKING
Phase equilibrium (3 phases)
Supply
Type : Aucun
CONTROL
Charge
Mode
Type : Modbus
Ufloat =
Regulation
Efficiency
0.47423 %
Ucharge =
V at In/2
413.13
483.45 V at In/2
Uboost =
X
1.0
1.0
95.0
498.10
NOK
Lim. Iboost =
U12
I1
U23
I2
U31
I3
PT
UDC
IDC
P( U x I )
0,1 In 455.5
62.0 A
PF
Ripple
VRMS
457.0
456.0
486.0 23.6
1.60
In
373.5
375.0
374.0
485.0 207.2
1.24
In
414.5 147.8
415.5
146.8
415.0 147.7
415.5
148.5
415.0 149.3
475.0 211.5
100346.5
96.77
0.98
2.30
2.09
SUBJECT
External aspect
IEC 529
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
Wiring
Identification
IEC 439
Cleaning
CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts
Tested by :
YMA
CHECKED
CUST.
COMMENTS
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Date : 31/7/2009
Charger Test
Checked by :
LDU Date :
Page
Reference
Index
12/08/09
PGE 18 UK
EQUIPMENT
INVERTER TEST
REPORT
LOAD
Item: UPS1+A1+INV
N: L08-1262
WO: 16939
RB: 318107
TAG CLIENT :
POWER SUPPLY
V 1 Ph
Hz
kVA
Voltage
110
Frequency
50
Power
70
2000 Vac
= / ground
Dielectric
2000 Vac
~ / ground
Dielectric
2000 Vac
~/=
Insulation
500 Vdc
R > 10 M
R < 0,10
Ah
310
293
Cells
Vented Ni Cd
Battery type :
OPTIONS
PRELIMINARY CHECK
Dielectric
V
A
370
209
Precharge DC
N/A
N/A
N/A
Output
Internal ligthning
Anti-condensation heater
Communication
Types : Modbus
Aucun
Inverter type
Fan failure
Transfer time
Signalling test
ON LINE
Main->Inv
OFF LINE
Inv->Main
0 ms
U =
0 ms
0.0 V
0.00
3.00 %
10.00%
572.00 V
X
X
NO LOAD TEST
Losses no load
Pv = 2381.4
Voltage no load
US = 109.90
F = 50.00
Hz
Frequency no load
CHECKING
Phase equilibrium (in 3 Ph)
Regulation
I = 602.0
Distortion = 3% at cos = 1
I = 574.7
Efficiency
Short circuit
I = 1246.0
REGULATION
Bridge type :
UDC
IDC
P( U x I )
N/A
1.0
X
X
92.0 %
IFH42S400
U12
U23
U31
I1
I2
A
I3
Ptotale
cos
485.0
18.2
8827.0
109.7
61.7
6768.5
76.7
2.6
Ubatt. High
In
482.0
152.7
73601.4
109.3
620.0
67766.0
92.1
2.7
Ubatt. Low
0,5 In
294.8
128.2
37793.4
109.5
318.1
34832.0
92.2
2.9
Ubatt. Low
In
294.5
246.7
72653.2
109.3
622.0
67984.6
93.6
2.8
SUBJECT
External spect
IEC 529
CHECKED
CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications
X
X
X
X
X
X
- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen
X
X
X
X
X
X
X
Wiring
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
X
X
X
X
X
X
Identification
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
X
X
X
X
X
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
IEC 439
Cleaning
COMMENTS
Comments :
Tested by : YMA
CUST.
X
X
X
X
X
X
X
Inverter test
Checked by :
LDU Date:
Page
Reference
Index
12/08/09
PGE 20 UK
EQUIPMENT
CHARGER TEST
REPORT
POWER SUPPLY
Item: CH2
N: L09-0831
WO: 15939
RB: 318107
LOAD
V 3 Ph
Hz
Voltage
415
Frequency
50
TAG CUSTOMER :
Battery type :
Ah
310
293
Cells
Vented Ni Cd
PRELIMINARY CHECK
Dielectric
2000 Vac
~ / ground
Equalizing / Floating
Dielectric
2000 Vac
= / ground
Equalizing / Floating
Dielectric
2000 Vac
~/=
Boost time
Insulation
500 Vdc
R > 10 M
Compensation U= f (C)
R < 0,10
V
A
370
209
min
X
N/A
X
62.0
15 H
mV / C / cells
N/A
A equalize / float
Time
Output
Input protection
Internal lightning
DC fuse tripping
Anti-condensation heater
Signalling test
Communication
Pv = 720.0
Losses no load
+ 10
- 10
Nominal U
Nominal U
I DC
CHECKING
Phase equilibrium (3 phases)
Supply
Type : Aucun
CONTROL
Charge
Mode
Type : Modbus
Ufloat =
Regulation
Efficiency
0.45417 %
Ucharge =
V at In/2
413.10
483.50 V at In/2
Uboost =
X
1.0
1.0
95.0
498.10
NOK
Lim. Iboost =
U12
I1
U23
I2
U31
I3
PT
UDC
IDC
P( U x I )
0,1 In 455.0
62 A
PF
Ripple
VRMS
456.0
455.0
485.1 19.4
1.40
In
374.0
375.0
375.0
484.4 206.2
1.40
In
415.0 149.0
416.0
147.0
415.0 149.0
416.0
148.0
415.0 149.0
472.0 209.7
99980.16
95.95
0.98
2.20
2.30
SUBJECT
External aspect
IEC 529
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
Wiring
Identification
IEC 439
Cleaning
CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts
Tested by :
MMO
CHECKED
CUST.
COMMENTS
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Date : 12/8/2009
Charger Test
Checked by :
LDU Date :
Page
Reference
Index
12/08/09
PGE 18 UK
EQUIPMENT
INVERTER TEST
REPORT
LOAD
WO: 15939
RB: 318107
POWER SUPPLY
V 1 Ph
Hz
kVA
Voltage
110
Frequency
50
Power
70
Item: INV2
N: L09-0831
TAG CLIENT :
2000 Vac
= / ground
Dielectric
2000 Vac
~ / ground
Dielectric
2000 Vac
~/=
Insulation
500 Vdc
R > 10 M
R < 0,10
Ah
310
293
Cells
Vented Ni Cd
Battery type :
OPTIONS
PRELIMINARY CHECK
Dielectric
V
A
370
209
Precharge DC
N/A
N/A
N/A
Output
Internal ligthning
Anti-condensation heater
Communication
Types : Modbus
Aucun
Inverter type
Fan failure
Transfer time
Signalling test
ON LINE
Main->Inv
OFF LINE
0 ms
Inv->Main
U =
0 ms
0.0 V
0.00
3.00 %
10.00%
572.00 V
X
X
NO LOAD TEST
Losses no load
Pv = 1680.0
Voltage no load
US = 110.00
F = 50.00
Hz
Frequency no load
CHECKING
Phase equilibrium (in 3 Ph)
Regulation
I = 602.0
Distortion = 3% at cos = 1
I = 574.6
Efficiency
Short circuit
I = 1190.0
REGULATION
Bridge type :
UDC
IDC
P( U x I )
N/A
1.0
X
X
92.0 %
IFH42S400
U12
U23
U31
I1
I2
A
I3
Ptotale
cos
484.0
20.2
9776.8
110.0
67.6
7436.0
76.1
2.4
Ubatt. High
In
483.0
160.0
77280.0
109.0
637.0
69433.0
89.8
2.5
Ubatt. Low
0,5 In
301.0
127.0
38227.0
109.5
319.3
34963.4
91.5
2.1
Ubatt. Low
In
300.5
255.0
76627.5
110.0
637.0
70070.0
91.4
2.4
SUBJECT
External spect
IEC 529
CHECKED
CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications
X
X
X
X
X
X
- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen
X
X
X
X
X
X
X
Wiring
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
X
X
X
X
X
X
Identification
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
X
X
X
X
X
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
IEC 439
Cleaning
COMMENTS
Comments :
Tested by : MMO
CUST.
X
X
X
X
X
X
X
Date: 12/8/2009
Inverter test
Checked by :
LDU Date:
Page
Reference
Index
12/08/09
PGE 20 UK
EQUIPMENT
CHARGER TEST
REPORT
POWER SUPPLY
Item: UPS2+A3+CH
N: L08-1262
WO: 16939
RB: 318107
LOAD
V 3 Ph
Hz
Voltage
415
Frequency
50
TAG CUSTOMER :
Battery type :
Ah
310
293
Cells
Vented Ni Cd
PRELIMINARY CHECK
Dielectric
2000 Vac
~ / ground
Equalizing / Floating
Dielectric
2000 Vac
= / ground
Equalizing / Floating
Dielectric
2000 Vac
~/=
Boost time
Insulation
500 Vdc
R > 10 M
Compensation U= f (C)
R < 0,10
V
A
370
209
min
X
N/A
X
62.0
15 H
mV / C / cells
N/A
A equalize / float
Time
Output
Input protection
Internal lightning
DC fuse tripping
Anti-condensation heater
Signalling test
Communication
Pv = 570.0
Losses no load
+ 10
- 10
Nominal U
Nominal U
I DC
CHECKING
Phase equilibrium (3 phases)
Supply
Type : Aucun
CONTROL
Charge
Mode
Type : Modbus
Ufloat =
Regulation
Efficiency
0.43299 %
Ucharge =
V at In/2
413.1
483.45 V at In/2
Uboost =
X
1.0
1.0
95.0
498.10
NOK
Lim. Iboost =
U12
I1
U23
I2
U31
I3
PT
UDC
IDC
P( U x I )
0,1 In 455.0
62 A
PF
Ripple
VRMS
457.0
456.0
485.0 23.6
1.63
In
373.0
375.0
373.0
485.0 207.0
1.30
In
414.5 146.9
416.5
146.0
415.0 145.9
417.0
147.1
415.5 147.6
474.0 211.1
100346.5
97.14
0.98
2.10
2.20
SUBJECT
External aspect
IEC 529
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
Wiring
Identification
IEC 439
Cleaning
CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts
Tested by :
YMA
CHECKED
CUST.
COMMENTS
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Date : 31/7/2009
Charger Test
Checked by :
LDU Date :
Page
Reference
Index
12/08/09
PGE 18 UK
EQUIPMENT
INVERTER TEST
REPORT
LOAD
Item: UPS2+A3+INV
N: L08-1262
WO: 16939
RB: 318107
TAG CLIENT :
POWER SUPPLY
V 1 Ph
Hz
kVA
Voltage
110
Frequency
50
Power
70
2000 Vac
= / ground
Dielectric
2000 Vac
~ / ground
Dielectric
2000 Vac
~/=
Insulation
500 Vdc
R > 10 M
R < 0,10
Ah
310
293
Cells
Vented Ni Cd
Battery type :
OPTIONS
PRELIMINARY CHECK
Dielectric
V
A
370
209
Precharge DC
N/A
N/A
N/A
Output
Internal ligthning
Anti-condensation heater
Communication
Types : Modbus
Aucun
Inverter type
Fan failure
Transfer time
Signalling test
ON LINE
Main->Inv
OFF LINE
Inv->Main
0 ms
U =
0 ms
0.0 V
0.00
3.00 %
10.00%
572.00 V
X
X
NO LOAD TEST
Losses no load
Pv = 2435.0
Voltage no load
US = 110.10
F = 49.99
Hz
Frequency no load
CHECKING
Phase equilibrium (in 3 Ph)
Regulation
I = 602.0
Distortion = 3% at cos = 1
I = 574.7
Efficiency
Short circuit
I = 1202.0
REGULATION
Bridge type :
UDC
IDC
P( U x I )
N/A
1.0
X
X
92.0 %
IFH42S400
U12
U23
U31
I1
I2
A
I3
Ptotale
cos
485.0
19.9
9651.5
110.0
61.6
6776.0
70.2
3.0
Ubatt. High
In
482.0
153.2
73842.4
109.2
619.3
67627.6
91.6
3.0
Ubatt. Low
0,5 In
295.6
127.5
37689.0
109.6
317.9
34841.8
92.4
3.0
Ubatt. Low
In
294.9
247.8
73076.2
109.2
622.0
67922.4
92.9
2.8
SUBJECT
External spect
IEC 529
CHECKED
CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications
X
X
X
X
X
X
- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen
X
X
X
X
X
X
X
Wiring
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
X
X
X
X
X
X
Identification
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
X
X
X
X
X
File conformity
IEC 439
Mounting
IEC 439
IEC 73H0354
IEC 439
Cleaning
COMMENTS
Comments :
Tested by : YMA
CUST.
X
X
X
X
X
X
X
Inverter test
Checked by :
LDU Date:
Page
Reference
Index
12/08/09
PGE 20 UK
CHLORIDE
INDUSTRIAL SYSTEMS
4. INSTALLATION
Title
Page
23
4.2. STORAGE
24
24
25
25
25
25
25
25
4.6.2. Battery
25
4.6.3. Neutral
26
4.6.4. Earth
26
4.7. VENTILATION
26
26
26
Page 23 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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.
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 0C to 40C it can be stored in temperatures as low as -20C.
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 -20C. 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.
Page 24 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Page 25 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
4.6.3. Neutral
Within the rectifier if no neutral-to-earth link is provided the rectifier neutral adopts the same
potential as the incoming Reserve Neutral if present. Therefore if the Reserve input has no
fixed neutral the rectifier 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 rectifier output.
4.6.4. 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
operation. Therefore Earth Leakage Trips (ELT) or RCCD on the input should take into
account this small leakage.
4.7. VENTILATION
All ventilation apertures must be kept free and clean. These systems can work in a continuous
environment within 0 to 40C temperature range, although, ideally the ambient temperature
should be below 25C.
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.
4.8. BATTERY-VENTED CADMIUM NICKEL
The battery is a vented cadmium nickel 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.
4.9. BATTERY INSTALLATION
WARNING:
Page 26 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Check the ambient temperature and once the system is running measure the temperature in the
battery cubicle.
Once the system is running check the charge voltage in:
FLOAT MODE
CHARGE MODE
BOOST MODE
Page 27 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
5. OPERATING INSTRUCTIONS
Title
Page
5. OPERATING INSTRUCTIONS
28
29
5.2. DISPLAY
30
31
32
32
33
36
41
42
5.10. HEADING
42
45
46
46
47
47
48
48
50
52
52
53
53
Page 28 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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
Green flashing
load on reserve, or
inverter running on
battery
Orange
UPS warning
Red
UPS fault
Red flashing
CAN communication
fault
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 can be lit simultaneously in
some circumstances.
Page 29 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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.
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.
Page 30 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
OK
Cancel parameters
Back in menus.
Rectifier
Inverter
Page 31 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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.
Charger
Battery
Inverter
Reserve
ACLoad
General menu
CHARGER
Status
ChangingMode
Measurements
Faults
Warnings
Charger menu
CHARGERMEASURES
UDC=220.1V
IDC=60.0Amp
U12=241.2V
U23=242.0V
U31=241.0V
I1=70.0Amp
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
Reset
Event log
Display Setting
Contact
About
Page 32 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
OK
to validate the chosen item and access to the sub-menu corresponding to this item.
NOTES:
The selected item is indicated by an arrow (4) at the beginning of the line.
Charger
Battery
Inverter
Reserve
ACLoad
Status
ChangingMode
Measurements
Faults
Warnings
Page 33 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
2. BATTERY
MENU
Charger
Battery
Inverter
Reserve
ACLoad
Status
Measurements
Faults
Warnings
3. INVERTER
MENU
Charger
Battery
Inverter
Reserve
ACLoad
Status
Measurements
Faults
Warnings
Page 34 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
4. RESERVE SUPPLY
MENU
Charger
Battery
Inverter
Reserve
ACLoad
This module is displayed only if a reserve supply network is confirmed on the customers technical
specification. This module allows entry to the following menus:
RESERVE
Status
Measurements
Faults
Warnings
5. AC LOAD
MENU
Charger
Battery
Inverter
Reserve
ACLoad
Status
Measurements
Faults
Warnings
Page 35 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Inverter
Reserve
ACLoad
Reset
BlackStart
ChargerReset
InverterReset
EventLogReset
AutonomCalculRst
Page 36 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Inverter
Reserve
ACLoad
Reset
BlackStart
This module is only available on parallel inverters. It allows entry to the following menu:
BLACKSTART
StarttheInverter
withoutReserve?
NO
YES
Page 37 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
3. EVENT LOG
MENU
Reserve
ACLoad
Reset
BlackStart
EventLog
This module allows to display one by one all the events memorised into the historical record, in a
chronological order.
Example of event:
EVENTN1
InverterFault
HighDCvoltage
Memorised
Initiated:
17fev0506:18:37
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 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.
N1 : the first event which has occurred (oldest).
N100: 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.
N1 : the most recent
N100: oldest. (if 100 recorded events).
See chapter 4 Display Setting for the selection of the Event Log Mode.
Page 38 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
4. DISPLAY SETTING
MENU
ACLoad
Reset
BlackStart
EventLog
DisplaySetting
Seriallink
Language
EventLogMode
Serial link menu (to direct the serial link of the display
board)
Internal
External
SelectedLink:
Internal
OK
English
French
Spanish
German
Italian
Page 39 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
EVENT LOG MODE: This module allows entry to the following menus indicating the two
possibilities.
EVENTLOGMODE
SaturableMode
FIFOMode
ActualSetting:
FIFOMode
5. CONTACT
This module allows access to CHLORIDE contact information.
6. 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 40 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
CHARGER
Status
ChangingMode
Measurements
Faults
Warnings
CHANGINGMODE
RequestAction
NoRequest
ChargerStatus
Floating
CHANGINGMODE
RequestAction
NoRequest
Floating
Equalisation
Boost
BatteryTest
Request action
Charger status
Page 41 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
or
navigating in the menus, the user can return to the active mimic diagram by pressing the
button as many times as necessary.
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.
Page 42 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
UPS running
AC load supplied
Inverter not synchronised on reserve
Charger status
Battery status
Synchronization status
Inverter status
10
AC load status
11
10
11
Page 43 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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
....
__
Page 44 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
NOTE 1:
has priority on
Pictogram voluntary OFF
has priority on .
Pictogram
and
NOTE 2:
When pictogram
appears on inverter block, it means that the inverter is not
synchronized with the reserve supply.
5.11. RECTIFIER/CHARGER INFORMATION
Status indications
Charger OFF
Initialisation
Charger Stop
Equalisation mode
Equalisation imposed
Floating mode
Battery test mode
Battery test imposed
Boost mode
Faults indications
No fault
High DC voltage
High DC voltage memorised
Too high I battery memorised
Charger fuse blown
Input protection open
Charger off
Wrong phase sequence
Warnings indications
Test mode
Fan failure
Overload inhibit
Charger in current limit
Measurements indications
Charger output DC voltage
Charger output DC current
Charger input voltage (between each phase)
Charger input current (on each phase)
Charger input frequency
Number of mains failures
AC supply fault
Page 45 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Faults indications
No fault
Battery test fault memorised
End of discharge
Battery protection open
Warnings indications
DC earth fault
Battery begin discharge
Imminent shutdown
Measurements indications
Battery voltage
Battery current
Battery temperature
Battery autonomy (%)
Warnings indications
No warning
Faults indications
No fault
Inverter switched off
VCE brigde fault memorised
Inverter overload fault memorised
Over-temperature fault memorised
Low DC voltage
Repeated low DC voltage memorised
High DC voltage memorised
Microcontroller fault memorised
High AC voltage memorised
Frequency fault memorised
Commissioning mode
Software time-out
Fan failure
Inverter overload warning
Measurements indications
Inverter input DC voltage
Inverter output voltage (between phases and
neutral)
Inverter frequency
Page 46 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Warnings indications
No warning
Reserve voltage fault
Reserve frequency fault
Wrong phase sequence
Measurements indications
Reserve voltage (between phases and neutral)
Reserve frequency
Faults indications
No fault
Static switch overload fault memorised
Inverter static switch fault memorised
Reserve static switch fault memorised
Static switch hardware fault memorised
Warnings indications
No warning
Manual bypass closed
Static switch overload
Measurements indications
Load voltage (between phases and neutral)
Load current (on each phase)
Load frequency
Load power (on each phase in kVA)
Load power (on each phase in kW)
Total time on inverter
Load current ratio (%)
Page 47 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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).
Close Q22: the inverters are now in TEST mode. After 10 seconds, the Reserve Static
Switch will be closed (visible on the synoptic diagram of the Displays).
On each display, check the correct display of the DC voltage (Inverter Measurement
Menu) and of the AC output voltage (AC Load Measurement Menu).
Page 48 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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).
Close Q23.
Open Q21.
Start both inverters by the control push buttons: both inverters will start simultaneously
once you start the second inverter.
Page 49 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
On the MPPOI-03 board in the Bypass cubicle, disconnect the 10-pin flat cable coming
from INVERTER M (INVERTER 1 is connected to SK1 and INVERTER 2 is connected
to SK2 of MPPOI-03).
Reset the inverter alarms on INVERTER R: Inverter block and Reserve are getting normal
again on the display.
In the Bypass cubicle, open the isolating terminals X943-A or X943-B connected to
INVERTER M.
Isolate INVERTER M from DC side: Stop the charger, open Q3 and open Q5. Be sure
that Q4 is also open. 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.
Before any maintenance operation, always make sure that no more voltage is present
on any part you will have to touch.
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.
Page 50 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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).
In the Bypass cubicle, close the isolating terminals X943-A or X943-B connected to
INVERTER M.
Operate an inverter reset by the control push buttons on both inverters, in order to clear all
Warnings and Faults.
On the MPPOI-03 board in the Bypass cubicle, connect the 10-pin flat cable coming from
INVERTER M (INVERTER 1 is connected to SK1 and INVERTER 2 is connected to
SK2 of MPPOI-03).
Page 51 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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.
Close Q21.
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 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.
Energise the DC supply. Wait until the display is correctly powered (no more question
mark).
Close Q22: the inverter is now in TEST mode. After 10 seconds, the Reserve Static
Switch will be closed (visible on the synoptic diagram of the Display).
Close Q23.
Open Q21.
Page 52 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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 the
Black Start, so you dont have to reset anything, once the Reserve Supply has come back.
Page 53 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
6. ROUTINE MAINTENANCE
Title
Page
6.1. GENERAL
54
54
54
55
6.5. ANNUALLY
55
6.6. FANS
55
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 54 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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 55 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
7. FAULT DIAGNOSIS
Title
Page
7. FAULT DIAGNOSIS
56
57
58
59
59
60
60
61
62
63
63
64
64
65
Page 56 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
on the charger
Page 57 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
CHARGER FAULTS
POSSIBLE CAUSES
SOLUTIONS
AC Supply fault
AC voltage NOK
High DC Voltage
High DC Voltage
Memorized
Page 58 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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)
7.3. CHARGER VOLUNTARY STOPPED
Charger switch Off
POSSIBLE CAUSES
SOLUTIONS
Fan failure
DC voltage low
Test mode
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 59 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
POSSIBLE CAUSES
SOLUTIONS
End of discharge
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. BATTERY WARNING
BATTERY
WARNINGS
POSSIBLE CAUSES
DC Earth fault
SOLUTIONS
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 60 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
on the
inverter pictogram.
Page 61 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
INVERTER FAULTS
POSSIBLE CAUSES
SOLUTIONS
VCE Fault M.
Overtemp. Flt M.
An overtemperature is detected on
the inverter bridge due to a problem
of cooling (possible fan failure or
air input /output blocked ).
Low DC voltage.
Repeated Low DC M.
High DC voltage M.
High AC voltage M.
Page 62 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Frequency Fault M.
Microcontroller fault
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
POSSIBLE CAUSES
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
PPVIS software.
Operator has forgotten to replace the
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.
S/W Time-out.
Commissioning
SOLUTIONS
Page 63 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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 doesnt imply a direct loss of the AC load.
RESERVE WARNINGS POSSIBLE CAUSES
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. AC LOAD/ STATIC SWITCH FAULT
AC LOAD/ STATIC
SWITCH FAULTS
POSSIBLE CAUSES
SOLUTIONS
Page 64 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
3 other AC LOAD/ Static Switch fault specific messages can be detected in this part due to
equipment customisation. Check this messages in the General Arrangement Drawing (PA)
7.13. AC LOAD/STATIC SWITCH WARNING
AC LOAD/ST.SW
WARNINGS
POSSIBLE CAUSES
AC Earth Fault
Manual Bypass On
SOLUTIONS
3 other AC LOAD/ STATIC SWITCH warning specific messages can be detected in this part
due to equipment customisation. Check this messages in the General Arrangement Drawing
(PA)
Page 65 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
8. SPARE PARTS
Titre
Page
66
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 66 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
9. DRAWINGS
Title
Page
67
PA-318107
SU
SU-318107
DT
- Technical file
DT-318107
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 to 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 67 of 68
Page
Titre/Title
00
01
02
03
04
TITLE PAGE
xx xx xx xx xx
GENERAL ARRANGEMENT
xx xx xx xx
xx xx xx
xx xx
xx xx
NAMEPLATE DETAIL
xx
05
06
07
08
09
10
11
12
13
CUSTOMER
PROJECT
EQUIPMENT
xx
XX
xx
xx
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
GENERAL ARRANGEMENT
03/09/2009
MHS
AS BUILT
04
29/07/2009
MCC
UPDATED
03
01/04/2009
MHS
02
16/03/2009
LML
01
07/11/2008
MHS
FOR APPROVAL
00
Date
Creat.
Description modif.
Indice/Issue
Verif.
App.
PA318107
Indice/
Issue
Page
04
Height :
Width :
Depth :
Protection :
Paint :
Lock :
Key :
Cable entry :
1982 mm
4800 mm
1008 mm
IP31
631 as per IS:5
Retractable Handle
1333
BOTTOM
=UPS1+A1
=BYP1+A2
=UPS2+A3
N
P
TAG A
1800mm
TAG B
TAG C
H1 H2 H3
H1 H2 H3
P
Hz
1982
H1 H2 H3
OPERATING HEIGHT
OF THE SWITCHES
LABEL / TAG :
100
TAG A : UPS 1
TAG B : BYP 1
TAG C : UPS 2
1180 kg
500 kg
1180 kg
1600
1200
1600
200 mini
WALL
1008
CHARGER
-H1 : CHARGER SUPPLY - PHASE 1 OK
-H2 : CHARGER SUPPLY - PHASE 2 OK
-H3 : CHARGER SUPPLY - PHASE 3 OK
BYPASS
-H1 : BYPASS SUPPLY - PHASE 1 OK
-H2 : BYPASS SUPPLY - PHASE 2 OK
-H3 : BYPASS SUPPLY - PHASE 3 OK
300mm
200 mini
282x120
282x120
282x120
282x120
182x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
182x120
282x120
282x120
282x120
282x120
282x120
282x120
SHIPPING BREAK
J.REQ.NO: 18-3293-00/O.65/0223/OO
800
GENERAL ARRANGEMENT
30/07/2009
MCC
Date
Creat.
Verif.
App.
UPDATED
Description modif.
PA318107
Ind/Rev
Page
03
1030
830
1600
92.5
92.5
1200
715.0
1008
715.0
830
715.0
1008
315.0
1430
13
72.5
J.REQ.NO: 18-3293-00/O.65/0223/OO
100
72.5
100
72.5
100
13
62.5
62.5
125
CENTRAL FOOT
DETAIL
MHS
Date
Creat.
Verif.
App.
PA318107
Ind/Rev
Page
02
282x120
182x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
282x120
131
282x120
60
182x120
131
60
1008
1600
1008
1200
77
109.0
189
77
79.5
77
159
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
MHS
Date
Creat.
Verif.
App.
PA318107
Ind/Rev
Page
02
STOP
Sync.
UPS
1 2 3
100%
100%
LED view
LED colour
OK
Description
Rectifier
Inverter
Comments
UPS normal
operation
Load on battery or on
reserve
Orange
UPS
WARNING
Red
UPS
FAULT
Red flashing
CAN communication
FAULT
Green
Green flashing
STOP
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
Select previous
Up in menus
Select next
Down in menus
OK
Cancel parameters
Back in menus
Valid parameters
Enter in menus
LML
Date
Creat.
Verif.
App.
PA318107
Ind/Rev
Page
01
Rectifier information
Inverter information
Status indications
Charger OFF
Initialisation
Charger Stop
Equalisation mode
Equalisation imposed
Floating mode
Battery test mode
Battery test imposed
Boost mode
Measurements indications
Charger output DC voltage
Charger output DC current
Charger input voltage (between each phase)
Charger input current (on each phase)
Charger input frequency
Number of mains failures
Faults indications
No fault
High DC voltage
High DC voltage memorised
Too high Ibattery memorised
Charger fuse blown
Input protection open
Charger off
Wrong phase sequence
AC supply fault
Warnings indications
Test mode
DC voltage low
Overload inhibit
Charger in current limit
Status indications
Inverter synchronised
Inverter on crystal
Inverter not running
Inverter switched off
Warnings indications
No warning
Commissioning
Software time-out
Fan failure
Inverter overload warning
Measurements indications
Inverter input DC voltage
Inverter ouput voltage (between phases and neutral)
Inverter frequency
Faults indications
No fault
Inverter switched off
VCE bridge fault memorised
Inverter overload fault memorised
Over-temperature fault memorised
Low DC voltage
Repeated low DC voltage memorised
High DC voltage memorised
Microcontroller fault memorised
High AC voltage memorised
Frequency fault memorised
Reserve information
Battery information
Status indications
Normal
Discharging
Charging
Fault or warning
Warnings indications
DC earth fault
Battery begin discharge
Imminent shutdown
Measurements indications
Battery voltage
Battery current
Battery temperature
Battery autonomy (%)
Faults indications
No fault
Battery test fault memorised
End of discharge
Battery protection open
REMOTE ALARM
Warnings indications
No warning
Reserve voltage fault
Reserve frequency fault
Wrong phase sequence
Status indications
No warning ; no fault
Warning ; no fault
No warning ; fault
Warning + fault
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
Measurements indications
Reserve voltage (between phases and neutral)
Reserve frequency
Faults indications
No fault
Static switch overload fault memorised
Inverter static switch fault memorised
Reserve static switch fault memorised
Static switch hardware fault memorised
Measurements indications
Load voltage (between phases and neutral)
Load current (on each phase)
Load frequency
Load power (on each phase in kVA)
Load power (on each phase in kW)
Total time on inverter
Load current ratio (%)
Warnings indications
No warning
Manual bypass closed
Static switch overload
LML
Date
Creat.
Verif.
App.
PA318107
Ind/Rev
Page
01
Quantit/quantity :
Matire/material :
Engraved plate
Epaisseur/thickness :
15/10me
Couleur de fond/background
colour :
Blanc/White
Couleur de caractres/letters
colour :
Noir/Black
Hauteur de caractres/letters
height :
2mm
Police/letters type :
SL513 ( Arial )
100mm
5mm
5mm
4 x 3.2
100mm
J.REQ.NO: 18-3293-00/O.65/0223/OO
AC Input Voltage :
Input Phases :
Input Frequency :
DC Voltage :
DC Current :
Battery Type :
Number of Cells :
Capacity :
Autonomy :
AC Output Voltage :
Output Phases :
Output Frequency :
415V
3
50Hz
370V
209.34A
CdNi
293
310Ah
60mn
110V
1
50Hz
Serial Number :
Equipment tag number :
L08-1262/L09-0831
38UPS-4-05/38UPS-2-03
Year of manufacture :
2008
NAMEPLATE DETAIL
29/07/2009
MCC
Date
Creat.
Verif.
App.
UPDATED
Description modif.
PA318107
Ind/Rev
Page
03
400mm
800mm
960mm
1000mm
1000 mm
800 mm
400 mm
IP31
631 as per IS:5
BOTTOM
1045mm
Height :
Width :
Depth :
Protection :
Paint :
Cable entry :
LOCKING
4x
FASTENING 9mm
760mm
845mm
12.5
BOTTOM
GLAND PLATE
310 x 96
35
310 x 96
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
LML
Date
Creat.
Verif.
App.
PA318107
Ind/Rev
Page
01
Page
Titre/Title
00
01
02
03
04
TITLE PAGE
xx xx xx xx xx
xx xx xx xx
05
06
07
08
09
10
11
12
13
CUSTOMER
PROJECT
EQUIPMENT
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
MHS
AS BUILT
04
30/07/2009
MCC
UPDATED
03
01/04/2009
MHS
02
16/03/2009
LML
01
07/11/2008
MHS
FOR APPROVAL
00
Date
Creat.
Description modif.
Indice/Issue
Verif.
App.
SU318107
Indice/
Issue
Page
04
=BYP1+A2
H1-H2-H3
-T31
70kVA
2Ph/415VAC -1Ph/110VAC
50Hz
X
-Q31
(200A)
BYPASS SUPPLY
TPN / 415VAC +/-10%
50Hz
Terminals Cu 50x5
-U31
100kVA
110VAC +/-1%
=UPS1+A1
APODYS
DISPLAY
H1-H2-H3
U, I, F
U, I
CHARGER 1
370VDC/147-208A
-Q3
(200A)
AC SUPPLY 1
TPN / 415VAC +/-10%
50Hz
Terminals Cu 50x5
-V2
(250A)
U
-Q2
(250A)
INVERTER 1 70kVA
1Ph/110VAC
50Hz
U
U, F
-V18
-Q26
(800A)
K100
=BAT1+A4
BATTERY 1 370VDC
Type
: NiCd
Reference : KBM 277
Number of Cells : 293
Capacity : 277h
Autonomy : 60min
BATTERY 2 370VDC
Type
: NiCd
Reference : KMB277
Number of Cells : 293
Capacity : 277Ah
Autonomy : 60min
Float
: 1.41V/cell
Charge
: 1.65V/cell
Manu. Boost : 1.70V/cell
End of Disch.: 1.00V/cell
-Q5_1
(250A)
(P40)
(P40)
U, F
-Q4
(250A)
U, F
-Q5_2
(250A)
(P40)
(P40)
-V21
-Q22
(800A)
U, F, I, W
-Q23
(800A)
K100
-Q21
(800A)
AC LOAD
1Ph / 110VAC
50Hz
Cu 50x5
U, F, I, W
=UPS2+A3
APODYS
DISPLAY
H1-H2-H3
U, I, F
X
-Q3
(200A)
AC SUPPLY 2
TPN / 415VAC +/-10%
50Hz
Terminals Cu 50x5
U, I
-V2
(250A)
-Q2
(250A)
CHARGER 2
370VDC/147-208A
SIZE OF TERMINALS
P6
: 0.14 to 4 mm
P8
: 0.2 to 6 mm
P10
: 0.5 to 10 mm
P12
:1.5 to 16 mm
P16
: 1.5 to 35 mm
P32 (M10) : 25 to 50 mm
P40 (M12) : 35 to 95 mm
P46 (M12) : 50 to 150 mm
P53 (M16) : 70 to 240 mm
Cu Busbars: Copper busbars
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
INVERTER 2 70kVA
1Ph/110VAC
50Hz
U
-Q
AUTO
TRANSITION
TEST
MAINTENANCE
U, F
-V18
-Q27
(800A)
21 22 23
NEUTRAL TO EARTH
XX
X XX
XX
X
INTERCONNECTION CABLES
NOT SUPPLIED BY CHLORIDE
30/07/2009
MCC
Date
Creat.
App.
DESCRIPTION
SU318107
Ind/Rev
Page
03
CHLORIDE
INDUSTRIAL SYSTEMS
10. ATTACHMENTS
Title
Page
10. ATTACHMENTS
68
68
Page 68 of 68
NCPP
Nickel Cadmium Pocket Plate
CONTENTS
1.0
TECHNICAL SPECIFICATION
2.0
INTRODUCTION
3.0
SAFETY PRECAUTIONS
4.0
5.0
STORAGE
6.0
INSTALLATION
7.0
ELECTROLYTE PREPARATION
10
8.0
ELECTROLYTE FILLING
11
9.0
CHARGING
12
10.0
MAINTENANCE
14
11.0
ELECTROLYTE REPLACEMENT
19
12.0
21
13.0
23
14.0
SERVICE LOG
24 -25
15.0
26
16.0
DRAWINGS
27
2.0 INTRODUCTION
We thank you for purchasing our reliable and long life nickel cadmium pocket plate
battery. Please read and follow the instructions given in this manual to obtain the
best performance and life from your battery. Inspect the battery at regular intervals
and use the service log sheet provided at the end of the manual for maintaining the
records. Contact Customer Service, for any additional help and guidance that you
may require.
2.1 ELECTROCHEMISTRY
The basic principle of the rechargeable battery is the conversion of electrical energy
into chemical energy and vice versa. The storage battery consists of a number of
individual cells connected in series to produce the required voltage. Each cell
consists of positive plates (containing nickel hydroxide as the active constituent)
and negative plates (containing cadmium hydroxide) immersed in a solution of
potassium hydroxide in DM/DI water with lithium hydroxide as an additive.
The simplified overall reversible electrochemical reaction given below produces a
nominal discharge voltage of 1.2 volts per cell:
2 Ni(OH)2 + Cd(OH)2
Charge
Discharge
2 NiOOH + Cd + 2H2O
When the cell is charged, the active materials initially present as hydroxides are
changed. The cadmium hydroxide is reduced to cadmium and nickel hydroxide
attains a higher degree of oxidation. On discharge, the process is reversed and the
active materials revert to their original state.
The potassium hydroxide electrolyte doesnt take part in these reactions and acts
only as a carrier of ions. The lithium hydroxide additive in the electrolyte
significantly increases the life of the cell since it has a beneficial effect on the
positive electrodes. This beneficial effect is more pronounced at higher operational
temperatures.
2.2
CONSTRUCTION
The first still the most reliable electrode design for nickel cadmium batteries is the
pocket plate. The active material in each electrode is encapsulated in pockets of
double perforated, nickel plated steel strips. Several pockets are mechanically
joined together and cut in suitable lengths to form plate pieces. Both cut edges of
the plate pieces are sealed by U-section steel strips. The nickel-plated steel tab is
joined to the plate piece and the U-section steel strips by spot welding. The plate
assembly is compressed together to establish good contact between the active
material, double perforated steel strips and U-section steel strips. The U-section
steel strips and tab are the Current collectors of the plate.
Several plates of the same polarity are either bolted to the terminal post or welded to
the terminal post. Negative and positive plate groups are interleaved so that plates
of opposite polarities are alternated. The plate groups are insulated from one another
by insulating each plate from the next by either a combination of insulating rods and
edge insulation or grid insulation. The plate block is firmly strapped together using a
suitable number of polypropylene straps.
The cell container is of the either polypropylene or stainless steel. Matching cell lids
are made of the same material as that of the cell container. Mirror welding is
employed for thermally fusing the mating surfaces of polypropylene cell containers
and lids, while TIG fusion welding is employed in case of stainless steel cell
containers and lids. The choice of material depends on the application and operating
conditions. The polypropylene containers are translucent and completely free from
corrosion in wet and saline conditions. The assembly is compact and easy, and the
polypropylene has high impact resistance.
Polypropylene cells are assembled on steel racks with step arrangement in order to
permit visual electrolyte level maintenance checks. Alternatively, polypropylene cells
are mounted in stainless steel crates, each holding a suitable number of cells to suit
the space constrained battery boxes as in the case of mobile applications.
Steel cell are mounted in insulated wooden crates, each holding a suitable number of
cells to suit the space constrained battery boxes as in the case of mobile
applications. The wooden crates are also placed in steel racks (without the step
arrangement) for stationary applications.
3.3
TOOLS
Use tools with insulated handles / surfaces.
Do not place or drop metal objects on top of the battery.
Remove rings, wristwatch, loose coins from the pockets and articles of clothing with
metal parts that might come in contact with the battery terminals.
Do not remove the transport seal (red plastic film), from the vent cap until ready to fill
the battery. Remove the transit cap (blue/red).
The battery electrolyte is supplied in either dry or liquid form. Dry electrolyte is
supplied in the separately sealed packages containing potassium hydroxide and
lithium hydroxide. Liquid electrolyte (a mixture of potassium hydroxide, lithium
hydroxide and DM/DI water in the required proportions) is supplied in sealed jerry
cans or drums.
Do not open the sealed packages or containers until ready to mix the electrolyte or fill
the battery.
Read the instructions for electrolyte preparation / or filling as required. Also remove
the transit cap (blue/red), wherever mounted on cell terminals for big size cells.
5.0 STORAGE
5.1 STORAGE OF NEW BATTERY IN FILLED AND CHARGED CONDITION
A filled and charged battery can be stored for a maximum period of one year.
Store the battery in a clean, dry and cool location. Cover the battery with a sheet of
plastic or similar protective cover to keep out water and shield against direct sunlight.
Do not store other material on top of the battery.
After removing from storage, the battery should be discharged to an average cell
voltage of 1.0 volt at 0.2 C5 Amps, and charged as per the instructions for first
charging.
5.2 STORAGE OF NEW BATTERY IN DRY & DISCHARGED CONDITION
A dry and discharged battery can be stored for prolonged periods, around ten years.
Store the battery in a clean, dry and cool location. Cover the battery with a sheet of
plastic or similar protective cover to keep out water and shield against direct sunlight.
Do not remove the plastic film sealing the flip top vent.
Do not store other material on top up of the battery.
After removing from storage, follow the instructions for electrolyte filing and first
charging.
5.3 STORAGE OF USED BATTERY IN FILLED & CHARGED CONDITION
If the battery is going to be left idle for a long period of time, but not more than one
year, it should be removed from service and properly stored.
Top up with DM/DI water to the maximum level mark and charge the battery to a fully
charging state.
Clean the battery thoroughly, and then coat the inter-cell and inter-crate connectors
with anti-corrosion oil.
Inter-crate connectors should be removed for cleaning, and then stored in a separate
package.
Store the battery in a clean dry, and cool location. Cover the battery with a sheet of
plastic or similar protective cover to keep out water and shield against direct sunlight.
Do not store other material on top up of the battery.
After removing from storage, the battery should be discharged to an average cell
voltage of 1.0 volt at 0.2 C5 Amps, and charged as per the instructions for first
charging. However, use only DM/DI water for adjusting the electrolyte level after
waiting for at least two hours after the first charge has been completed.
6
5.4
6.0 INSTALLATION
The battery should be installed in a clean and dry area.
The battery should never be placed direct on the floor where it is subject to
dampness and dirt accumulation.
Batteries do not give off corrosive gas and therefore can be installed together with
other electrical equipment.
To avoid accelerated ageing of the plastic due to ultra violet radiation, batteries using
plastic cell containers and lids should not be exposed to direct sun light for long
periods.
6.1 TEMPERATURE
Avoid placing the battery in a hot place or in front of a window.
The battery will give the best performance and maximum service life when working at
a temperature between 10 and 30 degrees centigrade.
With adequate electrolyte specific gravity, the battery will perform properly within the
temperature range 40 to + 50 degrees centigrade.
Freezing will not cause damage to the battery.
6.2
VENTILATION
During the last part of high-rate charging, the battery gives off gas
(oxygen-hydrogen mixture)
At normal float-charge the gas evolution is very small.
The ventilation requirement of the battery as per DIN 57510 can be expressed by the
relation :
Q=55 x N x I, where Q is the quantity of air to be replaced from battery room in
litres /hour.
N is the number of cells in the battery, and I is the charging current at the end of high
rate charging.
Normally, no extra means of ventilation (exhaust fan etc.) is needed unless the
battery room is extremely small in proportion to the size of the battery.
6.3
All racks are supplied with insulators. However, the racks also have provision for
direct bolting to the floor.
Assemble the racks with the help of the drawing, enclosed with this manual.
Position the cells on the rack suitably so as to permit connection of the positive and
negative terminals according to the wiring diagram.
FOLLOW THE POLARITY TO AVOID SHORT CIRCUITING OF THE CELLS.
Connect the battery terminals to the equipment only after marking all the other intercell and inter-row connections
ONLY NICKEL PLATED COPPER CABLE LUGS SHOULD BE USED.
NEVER USE ALUMINUM CABLES AT THE BATTERY TERMINALS.
Use the correct torque to tighten the terminal bolts as indicated below:
RECOMMENDED TORQUE
BOLT DIAMETER
M 5
M 8
M 10
B-22, Density
1.20
B-30,
Density1.28
Potassium
Hydroxide
(88-90%)
268 gms.
384 gms.
Lithium
Hydroxide
(55%)
40 gms.
54 gms.
Demineralised
Water
890 cc
840 cc
Cell Type
Standard
For special
Application(solar)
Use only clean vessels of plastic or steel for preparing the electrolyte. Copper,
aluminium or Galvanised Vessels must not be used. Do not use accessories already
used for lead acid batteries. Transfer the Electrolyte into the cells using a clean
plastic jug. The electrolyte must not be exposed to air for long periods. Ensure that
the electrolyte does not get contaminated.
7.2 GUARANTEE CONDITIONS
Use only electrolyte approved by HBL Nife Power Systems Limited, for our Ni-Cd
batteries.
10
8.0
ELECTROLYTE FILLING
Flip open the top of the vent or unscrew the cap in case of screw type vent cap and
remove the transport seal (plastic film) if you have not already done so.
Do not completely remove the vent for filling the cells, but only flip open the top of flip
top vent cap & unscrew the cap in screw type vent cap for easy access. Only special
spill proof vents like SUNICA vents require to be fully removed for electrolyte filling
and topping up.
Use the correct electrolyte as specified In the Technical Specifications and fill the
cells slowly until the level of electrolyte is about 15 mm below the maximum level
indication.
Check the cells after 30 minutes and add electrolyte upto max. level indication.
Check the Technical Specifications for correct levels of electrolyte before filling. This
is required for cells in stainless steel containers, since these containers are not
provided with the level indication stickers as in the case of cells in polypropylene
containers. Use the capillary tube provided for checking the electrolyte level in cells
with stainless steel containers.
The specific gravity of the B-22 electrolyte in the cell will now stabilize at 1.19 +/- 0.01
from the initial filling electrolyte with specific gravity 1.20 +/- 0.01.
For Special cells (for solar applications), the specific gravity of the B-30 electrolyte in
the cell will now stabilize at 1.26 +/- 0.01 from the initial filling electrolyte with specific
gravity 1.28 +/- 0.01.
11
9.0 CHARGING
The battery can be charged by all normal constant current and constant voltage
methods.
Batteries in parallel operation with charger and load are generally charged with
constant voltage.
In operations where the battery is charged separated from the load, charging with
either constant current or constant voltage can be carried out.
9.1 FIRST CHARGING (DURING COMMISSIONING)
The cell vent caps should be closed during charging. Ensure that the transport seal
strip used for preventing electrolyte spillage during transportation has been removed
before charging. Also ensure that the transit caps (blue / red), wherever mounted on
cell terminals for big size cells.
First charging should be done using constant current only.
Charge the battery with the current recommended in the Technical specifications.
The duration of charge should be such that a charge input of 200% of C5 AH is given.
If the charger maximum voltage setting is too low to supply constant current charging,
divide the battery into two parts to be charged individually.
The charger must be able to work continuously at current limit without being
damaged. HBL NIFE chargers can do this.
A generous first charge with 200% charge input is important for obtaining maximum
battery performance.
Add electrolyte after waiting for a period of at least two hours after the first charge
has been completed.
At the same time, check the electrolyte density and adjust if necessary within the
specified limits.
After this final adjustment, the quantity of electrolyte in the battery is correct and
battery is ready for service.
Electrolyte should not be added later. For normal topping up, only DM/DI water
should be used.
THE ELECTROLYTE DENSITY IS NOT AFFECTED BY THE STATE OF CHARGE
OF THE BATTERY.
12
13
10.0
MAINTENANCE
10.1 CLEANLINESS
It is important to keep the battery dry and clean. This will contribute to top the
performance and maximum service life and non-contamination of cells during topping
up.
If potassium carbonate crystals (grey white deposits) form on top of the battery, rub
with a soft brush and wipe with a clean damp cloth followed by a clean dry cloth.
Do not use a wire brush or solvents of any kind, such as gasoline, thinner, acetone,
kerosene etc.,
10.2
VENT CAPS
Vent caps should be kept clean to avoid blocking of holes and prevent venting of
gases produced during charging.
Vent caps can be removed from the cells, rinsed in clean water, dried and replaced,
vent caps can also be cleaned by wiping with a clean damp cloth followed by a clean
dry cloth while mounting on the cells.
10.3 CONNECTORS
Check at least once a year that all connectors are tight. This is especially important if
the battery is subjected to vibration or shocks during service.
The connectors and terminal screws should be corrosion protected by coating with a
thin layer of anti-corrosion oil / petroleum jelly.
10.4
TOPPING UP
The electrolyte level should be always-within the maximum and minimum level marks
by replenishing the water.
Use only DM/DI water for toping up.
It is not necessary to add water frequently in an attempt to keep the electrolyte at
maximum level.
Never let the level fall below the top of the plates.
Do not add water to the maximum level during high rate charge since accurate level
reading is not possible when the battery is gassing.
Avoid splashing water when topping up. A wet battery can result in earth faults and
/or erratic operation.
Always keep the flame arresting vents closed except for the moment of topping up.
10.5
10.8
TROUBLE SHOOTING
Even though HBL Nife Power Systems Limited nickel cadmium batteries themselves
are very reliable and trouble free, they are part of a larger system that can introduce
abnormal conditions, and batteries are also exposed to different quality of
maintenance.
The following list of possible problems, causes and action will be of good use.
S.No.
01.
SYMPTOM
PROBABLE CAUSE
RECOMMENDED CORRECTIVE
ACTION
Erratic
charger Wrong polarity of cell, Check each cell or block for correct
behaviour
block, row of battery.
polarity.
Interruption at
connector
Interruption
empty cell
Faulty charger
15
See
charger
troubleshooting.
instructions
for
S.No.
02.
SYMPTOM
Earth fault
indication
PROBABLE CAUSE
Small leak or leaks
Battery wet
overfilling
03.
04.
05.
due
RECOMMENDED CORRECTIVE
ACTION
Check for wetness on battery stand,
or with a voltmeter, area of the battery
having the lowest potential to ground.
See (1) for procedure if a cell is
leaking.
to Disconnect few connectors to avoid
high or over boiling voltage and clean
the battery. See (8).
Other equipment of
system
Continuous
Charging voltage is
heavy gassing
above
the
recommended
float
voltage .
No power or Interruption
at
capacity at all
connector
Too
short
discharge time.
The
voltage
decreases
quickly at the
end.
16
S.No.
06.
SYMPTOM
PROBABLE CAUSE
Low
discharge Very low voltage for
voltage during a one or few cells.
major
part
of
discharge.
07
08
RECOMMENDED CORRECTIVE
ACTION
Check the individual cell voltages during
discharge and full recharge. If the
voltage of an individual cell does not
come up nearly as high discharge. As
others, the cells have a partial short
circuit and therefore not accepting
charge. (If the charging voltage is fine
but the cell voltage collapses early in
the discharge the cell capacity is
abnormally low). The reason could be
unsuitable handling at installation or
contamination in the electrolyte.
This condition sometimes occurs if the
design cell end voltage is 1.14 1.18
volt per cell and the battery has been in
service for sometime. It does not mean
that the capacity has decreased. It is
best handled by using more cells in the
battery and thus lowering the final cell
voltages, and high rate or boost
charging now and then.
Insufficient charging, See(06)
battery
Too
low
for Discharged
engine
starting. due to insufficient
The engine does charging
not turn at all, or
with
too
low
speed to fire
Loose connector
Tighten all connectors. For high power
discharges this is very important, both
from a performance and safety
viewpoint. A loose connector will cause
voltage drops and can spark and ignite
charging gasses.
Too low temperature
If the temperature is lower than the
design temperature for the starting
system, it will be difficult to start
because the battery gives less power
whereas the engine requires more
power to turn. Use the correct engine oil
for the temperature and try to arrange
preheating of the engine and battery if
possible.
Engine trouble
If cranking speed appears to be good,
failure to start may depend on the fuel
or engine. The battery can not do more
than crank engine at sufficient speed.
Wet battery
Overfilling or over Disconnect a few connectors to avoid
boiling
high voltage and clean the battery. Use
proper filling equipment to avoid
overfilling. Over boiling is the result of
too high electrolyte level and high rate
charging. Normal level and charging at
too high rate may also cause over
boiling.
17
S.No.
SYMPTOM
PROBABLE CAUSE
RECOMMENDED CORRECTIVE
ACTION
Sudden eruption of Disconnect a few connectors to avoid
electrolyte from one high voltage and clean the battery. Fill
cell
the electrolyte or DM/DI water in the
cell, which has lost the electrolyte and
charge the cell individually. Then
replace the cell in the battery and
recharge the complete battery. Check
the individual cell voltages.
If one cell in a battery with high
current load such as engine starting is
completely discharged it may spew
out electrolyte when the high current
is applied.
Electrolyte leakage at After sometime in service, electrolyte
posts and vents.
may penetrate the seals around the
posts, vents and connectors. In the
normal cleaning of the battery, it does
not affect the performance of the
battery to any extent.
Electrolyte
leakage A leakage through a pore or small
through
pores
or crack could be so small that it does
cracks.
not affect the electrolyte level
noticeably, but will cause earth faults
and the cell or block should be
replaced.
09
Uneven
Poor filling or topping If the levels of electrolyte vary
electrolyte levels up.
throughout the battery, the reason is
in the battery
probably poor topping up or leveling
off after filling.
Different float voltages
Leaking cell
18
11.0
ELECTROLYTE REPLACEMENT
In most stationery battery applications, the electrolyte will retain its effectiveness for
the life of the battery. However, under special battery service conditions, such, as
high temperature and / or frequent cycling, potassium carbonate build up in the
electrolyte may reach a level that will influence the battery performance. If the
potassium carbonate reaches a level of about 25 % of the electrolyte, is said to be
carbonized, and the battery performance can be restored to a great extent by
replacing the electrolyte.
The type of electrolyte to be used for replacement is given below.
CEL L TYPE
Standard
ELECTROLYTE TYPE
FOR FIRST FILLING
ELECTROLYTE TYPE
FOR REPALCEMENT
ELECTROLYTE TYPE
FOR COMMISSIONING
IF SUPPLIED DRY
POTASSIUM
HYDROXIDE
(88-89%)
LITHIUM
HYDROXIDE
(55%)
DM/DI
WATER
276 gms..
9 gms.
910 cc.
363 gms.
22 gms.
870 cc.
Use this data as proportions for preparing the electrolyte for the battery in suitable
batch quantities depending on the size of the vessels available for electrolyte
preparation.
11.2 DISCHARGE
Before emptying the electrolyte, discharge the battery to a voltage corresponding to
about 0.6 volt/cell with a current not higher than of 0.2 C5 Amps. The plates shall
never be exposed to atmosphere in charged condition.
11.3 EMPTYING
Open the vents and place the battery inverted to drain the cells. Let the cells drain for
about 5 minutes. Do not shake the cells.
Beware of electrolyte splashes.
Do not rinse with water, as this may cause trouble in obtaining correct electrolyte
19
FILLING
Immediately after emptying, fill the cells according to the instructions for the
electrolyte filling.
11.5
CHARGE
Charge the battery according to the instructions for first charging.
A generous charge is important for the restoration of the battery performance.
20
21
12.2 DO NOTS
22
CALCULATED AS
TOPPING UP
WATER MAXIMUM
g/l
WATER FOR
PREPARATION OF
ELECTROYTE
MAXIMUM g/l
Chloride
KCl
Traces
0.06
Sulphate
K2SO4
Traces
0.05
Nitrate
KNO3
Traces
Traces
Silico
SiO2
Traces
Traces
Aluminium
Al2O3
Traces
Traces
Calcium &
Magnesium
CaO+MgO
Traces
Traces
Traces
0.03
0.05
0.15
0.03
0.06
Heavy Metals
Evaporation
Organic
impurities
KMNO4
Note : Topping up must be with DM/DI water with the conductivity less than 10 micro
siemens /cm
23
CELL NOS
DISCREPANCIES NOTICED
24
CELL NOS
DISCREPANCIES NOTICED
25
26
16.0 DRAWINGS
27
Corp.Mktg/12-2003/NCPP/O&S