Uninterruptible Power Supply SOLA 4000 OPERATING MANUAL JUE 401263
Contents of JUE 401263 SOLA 4000 Operating Manual The SOLA 4000 Operating Manual consists of the following documents: SECTION 0: JUE 401263 INDEX AND SAFETY INSTRUCTIONS SECTION 1: JUE 401264 GENERAL SYSTEM DESCRIPTION SECTION 2: JUE 401265 INSTALLATION AND INITIAL START-UP SECTION 3: JUE 401266 OPERATION SECTION 4: JUE 401267 OPERATING PANEL SECTION 5: JUE 401268 PCB DESCRIPTION SECTION 6: JUE 401269 TECHNICAL DATA We reserve the right to modify the contents of this document without
SOLA 4000 - Operating Manual Safety Instructions SAFETY INSTRUCTIONS The unit must be used as intended. Follow the instructions given in the Operating Manual. Dangerous voltages are present inside the unit. Installation and use of this equipment must comply to all national and local regulations and procedures. To prevent overheating do not obstruct the flow of air for ventilation openings to the unit. The components inside the unit are not repairable by the user.
SOLA 4000 - Operating Manual Safety Instructions Earth leakage protection: this device has a high leakage current towards protective earthing. The maximum earth leakage current is 300 mA. When setting the threshold of the earth leakage circuit breaker installed upstream from this equipment consider this amount of current and that due to the loads.
Contents of JUE 401264 SOLA 4000 - General System Description Figures Chapters 1 UPS ASSEMBLY 2 1.1 Features 2 FIG. 1.1 UPS Block-Diagram 3 1.2 UPS System Structure 3 FIG. 1.2 Rectifier Block-Diagram 3 1.3 Rectifier/Battery Charger 3 FIG. 1.3 12-Pulse Rectifier Block-Diagram 3 1.4 Battery (Accumulator) 4 FIG. 1.4 Inverter Block-Diagram 4 1.5 Inverter 4 FIG. 1.5 Static Switches Block-Diagram 4 1.6 Static Switches 4 FIG. 1.6 Maintenance Bypass Block-Diagram 6 1.
SOLA 4000 - General System Description 1 UPS Assembly 1 UPS ASSEMBLY 1.1 Features CE UPS Function This equipment complies to the essential requirements of European Directives 89/336/EEC and 73/23/EEC, and complies to EN50091-2 (1995) and EN50091-1 (1991) standards. The uninterruptible power supply (UPS) is connected between the consumer's critical equipment (the load) and supply mains. Its function is to guarantee a continuous and conditioned power supply to the load.
SOLA 4000 - General System Description 1 UPS Assembly 1.2 UPS System Structure The basic SOLA 4000 power supply unit is an ac/dc/ac converter; the block diagram: Figure 1.1 illustrates six essential functional components: • Rectifier/battery charger (6 pulse) (RECT.) • Battery (BATT.) • Inverter (INV.) • Static inverter switch (SSI) • Static bypass (SSB) • Maintenance bypass (IBY) All components are located in a single housing. They are explained in detail on the following pages.
SOLA 4000 - General System Description 1 UPS Assembly 1.4 Battery (Accumulator) The battery supplies power in case of a short interruption or a total breakdown of the ac mains supply. In case of a rectifier failure (no dc voltage output), the load will be fed by the battery. The battery is only capable of feeding the load for a certain time (autonomy time), depending on battery capacity and actual load.
SOLA 4000 - General System Description 1 UPS Assembly During overload or inverter failure conditions, SSI is switched off and SSB is switched on, providing power supply from a backup source (mains, output of another UPS system, diesel generator set....). By always actuating both switches together for a short period, an uninterrupted power supply during the switching is ensured. This is an essential condition to reliably meet all power supply requirements for connected sensitive equipment.
SOLA 4000 - General System Description 1 UPS Assembly 1.7 Maintenance Bypass The maintenance bypass function is to supply power directly to the connected load during UPS maintenance. The bypass consists essentially of one switch IBY. With SOLA 4000 series UPS systems, switching from different operating modes to maintenance bypass can be performed without interruption.
SOLA 4000 - General System Description 1 UPS Assembly 1.9 Parallel-Redundant Systems A parallel UPS system consists of 2 to 8 single UPS units connected in parallel, sharing the load current equally. Each unit has an individual static bypass, thus ensuring also redundancy of the static bypasses in a redundant system, i.e. if one static bypass should fail, the bypass system will still be available. There is no common electronic device for the parallel system.
SOLA 4000 - General System Description 2 Operating Panel 2 OPERATING PANEL 2.1 Functional Description The operating panel is the user-interface of the UPS.
Contents of JUE 401265 SOLA 4000 - Installation and Initial Start-Up Chapters 1 Figures INSTALLATION 3 1.1 Mechanical Installation 3 FIG.1.1.1 Moving the UPS 10-60kVA units 3 1.2 Electrical Installation 8 FIG.1.1.2 10-60kVA UPS floor space 4 1.3 Install. of Additional Optional Cabinets 13 FIG.1.1.3 80-120kVA UPS floor space 4 1.4 Installation of an External Maintenance Bypass 16 FIG.1.1.4 AC001 transformer cabinet 4 1.5 CPNET Interface Card 18 FIG.1.1.
SOLA 4000 - Installation and Initial Start-Up SOLA 4000 - Installation and Initial Start-Up FIG.1.8.1 Connec. of remote common alarm 22 Figures FIG.1.9.1 Connection of remote reset 22 FIG.1.10.1Interconnection of hot-standby units with integrated maintenance bypasses and separate bypass terminals 23 FIG.1.10.2Interconnection of hot-standby units with external maintenance bypass and separate bypass terminals. 24 FIG.1.10.3Interconnection of control BUS cable for hot-standby units 25 FIG.1.11.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1 INSTALLATION 1.1 Mechanical Installation Equipment Delivery and Storage Handling the UPS System After delivery, check equipment for any damage that may have occurred during shipment. The shipper and your SOLA agency must be notified in writing about damages due to shipment, including a detailed description of visual defects.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Weight Type SOLA 4000 Weight Weight Static without with Load Battery Battery [kg] [kg] [kg/m²] 10 310 597 1277(*) 15 310 597 1277(*) 20 335 622 1330(*) 30 350 637 1362(*) 40 480 - 1026 60 520 - 1112 80 810 - 1176 100 840 - 1219 120 870 - 1263 TAB. 1.1.1 UPS weight Floor Space Required FIG. 1.1.2 10-60kVA UPS floor space FIG. 1.1.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Room Size for 10-60 kVA UPS FIG. 1.1.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Room Size for 80-120 kVA UPS with auxiliary AC001 cabinet AC001 cabinets are used for SOLA 4000 units with 12 pulse chargers without galvanic separation and with THD Filters. FIG. 1.1.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Room Size for 80-120 kVA UPS with auxiliary AC002 cabinet AC002 cabinets are used for SOLA 4000 units with 12 pulse chargers with galvanic separation and with auxiliary transformers. FIG. 1.1.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.2 Electrical Installation This equipment must be installed by qualified service personnel. Switch off IRP, IRE, IB, IUG, IBY circuit breakers to completely isolate the equipment. Earth leakage protection: this device has high leakage current towards protective earthing. Earth leakage circuit breakers shouldn't be installed upstream from this equipment or a correct threshold should be set.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Version 1 SOLA 4000 with Common Input for Rectifier and Bypass FIG. 1.2.1 UPS connection diagram, version 1 (*) Note: Internal Battery only for 10-30kVA units (**) Note: Customer supplied input fuses - see table 1.2.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Version 1 SOLA 4000 with Common Input for Rectifier and Bypass Input Cables / Fuses Type SOLA 4000 Input Input cables fuses [mm²] [A] earth cable [mm²] 10 4x10 25 16 15 4x10 35 16 20 4x16 50 16 30 4x25 63 25 40 4x35 100 25 60 4x35 125 25 80 4x70 160 50 100 4x70 200 50 120 4x120 250 70 TAB.1.2.1 UPS input cables and fuses, version 1 Output / Battery Cables and Max. Current Ratings for Battery Overcurr.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Version 2 SOLA 4000 with Separate Inputs for Rectifier and Bypass FIG. 1.2.2 UPS connection diagram, version 2 (*) Note: Internal Battery only for 10-30kVA units (**) Note: Customer supplied rectifier input fuses - see table 1.2.5 (***) Note: Customer supplied bypass input fuses - see table 1.2.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Version 2 SOLA 4000 with Separate Inputs for Rectifier and Bypass Input Cables Type SOLA 4000 Rect. Bypass earth cables cables cable [mm²] [mm²] [mm²] 10 3x10 4x10 16 15 3x10 4x10 16 20 3x16 4x16 16 30 3x25 4x25 25 40 3x25 4x25 25 60 3x35 4x35 25 80 3x50 4x50 50 100 3x70 4x70 50 120 3x120 4x120 70 TAB. 1.2.3 UPS input cables, version 2 Input Fuses Type SOLA 4000 Rect.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.3 Installation of additional optional cabinets SOLA 4000 with input and output transformers for voltage adaption FIG. 1.3.1 UPS connection diagram, with input and output transformers to adapt the UPS to the on-site voltage. SOLA 4000 with isolation transformer of the bypass supply FIG. 1.3.
SOLA 4000 - Installation and Initial Start-Up 1 Installation SOLA 4000 with THD filters FIG. 1.3.
SOLA 4000 - Installation and Initial Start-Up 1 Installation SOLA 4000 with 12-pulse charger / rectifier FIG. 1.3.4 Installation of 12-pulse units without galvanic isolation SOLA 4000 with 12-pulse charger / rectifier and galvanic isolation of the input supply. FIG. 1.3.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.4 Installation of an External Maintenance Bypass When an external maintenance bypass is installed, a normally open, voltage free contact must be available. This contact must be connected to the connector M4, Pin1 and Pin 2 at the top left hand corner of the mother board for the inverter/bypass electronics (IBYBP-CP see figure 1.10.3).
SOLA 4000 - Installation and Initial Start-Up 1 Installation FIG.1.4.2 External Maintenance Bypass Switch Version 2 (3 position) Note1: For Hot-Standby or parallel systems, it is sufficient to feed one contact into one unit only, however they may be connected in parallel at M4 (of IBYBP-CP) Pin1 and Pin 2 for all units. In this case separate terminals may be provided within the MB3 cabinet (see FIG. 1.9.2 and 1.10.2) Note2: The cable used must be twisted pair, with a total shield.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.5 CPNET Interface Card The CPNET interface card is used for remote signalling of four standard alarm conditions by means of voltage-free contacts in programmable configurations. 1.5.1 Installation The CPNET interface card is a small pcb that is installed directly underneath the CPU/NCP pcb, inside the front door of the UPS cabinet. It is connected to the UPS via the connector CN1 on the CPNET pcb to CN10 on the CPU/NCP pcb.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Pin CN2 Pin M1 1 1 2 2 N - MF* - MF* MF* MF* 3 3 MF MF MF MF MF MF MF 4 4 5 5 BL BL BL BL BL BL BL 6 6 B MOK - - MOK MOK MOK 7 7 BOK BOK BOK BOK BOK BOK BOK 8 8 - - - - BL* - - 9 9 0V 10 Not Used AS400 NOVEL 3-COM BANYAN-VINES BORRI VIKING BORRI AMERICAN SIDEKICK POWER Not Used Common TAB. 1.5.2.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.6 Remote Emergency Power off A Remote Emergency Power Off may be connected to the system. The connection terminals are M4 Pin 5 and Pin 6, using a normally-open, voltage-free contact as a pushbutton.(See FIG. 1.6.1. and FIG 1.6.2.) FIG. 1.6.1 Connection of Remote EPO with N.C. contact FIG. 1.6.2 Connection of Remote EPO with N.O. contact Note 1: The cable used must be twisted pair, with a total shield.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.7 Diesel - Generator Operation During diesel generator operation, if the frequency of the dieselgenerator, with UPS and load connected, is unstable, it is advisable to disconnect the synchronisation of the inverter. This is achieved with a normally-open, voltage-free contact (which closes during diesel-generator operation) and is connected to the connector M4 Pin 7 and Pin 8 as follows: FIG. 1.7.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.8 Common Alarm Contacts As a standard feature, contacts are provided for a remote common alarm.The connector is located on the control p.c.b for the front operating panel (CPU/NCP), located inside the front door of the UPS. FIG. 1.8.1 Connection of Remote Common Alarm Nominal Rating of Contacts 125 V ≅ 30 V ≅ 0,5 A 60 W 2A 60 W TAB. 1.8.1 Nominal Rating of contacts for the common alarm.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.10 Installation of Hot-Standby Systems For hot-standby systems the units must be connected together as shown in the FIG. 1.10.1 or FIG. 1.10.2 Note: The installation for each unit must be performed in accordance to the installation of single units as described in the previous sections. Additionally to this, the outputs must be connected in parallel as shown in FIG. 1.10.1 or in FIG.1.10.2 FIG. 1.10.
SOLA 4000 - Installation and Initial Start-Up 1 Installation FIG. 1.10.2 Interconnection of hot-standby units with external maintenance bypass and separate bypass terminals. (*) Note: The internal maintenance bypass (IBY) may or may not be installed in this configuration. (**) Note: This cable must be twisted pair, total shield (refer. to section 1.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.10.1 Installation of the Interconnection Cable The supplied cable must be connected between the units within the system. This must be connected at either of the connectors CN12 or CN13 on the mother-board of the Inverter/Bypass electronics (IBYBP-CP) and the other end of the cable is connected to either CN12 or CN13 on the mother-board of the Inverter/Bypass electronics (IBYBP-CP) of the other unit(s).
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.11 Installation of Parallel Systems Up to a total of 8 units may be installed together in the one parallel system. Note: The installation for each unit must be performed in accordance to the installation of single units as described in the previous sections. Additionally to this, the outputs must be connected in parallel as shown in FIG. 1.11.1 or in FIG.1.11.
SOLA 4000 - Installation and Initial Start-Up 1 Installation FIG. 1.11.1 Interconnection of parallel units with integrated maintenance bypasses and separate bypass terminals.
SOLA 4000 - Installation and Initial Start-Up 1 Installation FIG. 1.11.2 Interconnection of parallel units with common maintenance bypass and separate bypass terminals. (*) Note: The internal maintenance bypass may or may not be installed in this configuration. (**) Note: This cable must be twisted pair, total shield (refer to section 1.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.11.1 Installation of the Interconnection Cables There are two interconnection cables supplied with the units for each additional unit to the first unit. These cables must be connected between the units as shown in FIG. 1.11.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.12 Battery Installation Battery Installation must be in accordance with local safety standards. General The batteries are charged. The installation should only be made by appropriately qualified personnel. The screw connections between the batteries should be tightened with a torque wrench (max. 7 Nm). 1.12.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Internal Electrical Connections Cable (1) n° 3; L = 280 mm; diameter 16 mm2 Cable (2) n° 8; L = 420 mm; diameter 16 mm2 Cable (3) n° 4; L = 490 mm; diameter 16 mm2 Cable (4) n° 2; L = 650 mm; diameter 16 mm2 Support (CA1) n° 4; See Fig. CA1 Support (CA2) n° 9; See Fig. CA2 FIG. 1.12.1 Internal Battery connections. Copper bars for battery connection Two copper plates diam. 0,5 mm. are used.
SOLA 4000 - Installation and Initial Start-Up 1 Installation 1.12.2 Installation of External Batteries External Battery (38 Ah) Installation 38 Ah external batteries are installed in a B3/38 battery cabinet. To assemble the battery cabinet: • Place four battery blocks on the trays of the first level (see FIG. 1.12.2). • Place six battery blocks on the trays of the second and third levels (see FIG. 1.12.3). • Interconnect the blocks in series (block 1 / negative pole ==> block 2 / positive pole,....
SOLA 4000 - Installation and Initial Start-Up 1 Installation Important: Open battery switch IB before connecting the cables. • Place the trays with the batteries on the corresponding levels in the UPS. • Connect the battery blocks of the various levels to the battery switch IB, and IB to the terminals, as shown in FIG. 1.12.5 and FIG. 1.12.6 Ensure appropriate ventilation of the battery room according to the standard EN50091-1, to prevent the risk of an explosion.
SOLA 4000 - Installation and Initial Start-Up 1 Installation FIG. 1.12.
SOLA 4000 - Installation and Initial Start-Up 1 Installation External Battery (65 Ah) Installation 65 Ah external batteries are installed in a B3/65 battery cabinet. To assemble the battery cabinet: • Remove the battery switch IB and the terminals. • Insert the battery blocks from the front and rear sides. Warning: after assembly there is a voltage of 192 V at the front and rear side. • Remount the battery switch IB and the terminals. Important: Open battery switch IB before connecting the cables.
SOLA 4000 - Installation and Initial Start-Up 1 Installation FIG. 1.12.
SOLA 4000 - Installation and Initial Start-Up 1 Installation Connection Between UPS and Additional Battery Cabinets Important: Open all battery switches IB before connecting the cables. Observe the indicated wiring polarity. • For UPS systems with external batteries: connect the external batteries as shown in FIG. 1.12.10 • After wiring, check that the external battery is connected with correct polarity. FIG. 1.12.
SOLA 4000 - Installation and Initial Start-Up 2 Initial Start-Up 2 INITIAL START-UP 2.1 Start-Up Procedure General Preparation A: Rectifier Power Supply Check ? yes no With the Start-Up procedure the correct installation of the UPS according to the previous section is checked. It must be carried out by specialised personnel. Safety precautions according to the appropriate local safety standards must be applied. Should problems arise during the Start-Up Procedure, call for service assistance.
SOLA 4000 - Installation and Initial Start-Up 2 Initial Start-Up B: Inverter Voltage Adjustment ? no yes C: Inverter free-run frequency check • On the SS/FY pcb, measure the voltage at the screws Inverter R, Inverter S, Inverter T with respect to the neutral terminal 5N. Does this voltage correspond to the desired voltage? • Adjust the voltage to the desired value individually for each phase using P3, P4 and P5 on the ICT-2 pcb.
SOLA 4000 - Installation and Initial Start-Up 2 Initial Start-Up • If your unit has separate supplies for the rectifier and bypass (terminals 4-L1, 4-L2, 4-L3, 4-N), switch on the external supply for the bypass. Check that the bypass supply voltage at terminals 4-L1, 4-L2, 4-L3, 4-N is within ±10% of the nominal input voltage. If there are no separate input terminals then the bypass input is the same as that checked previously for the rectifier input. • Close IUG. • Close IRE.
SOLA 4000 - Installation and Initial Start-Up 2 Initial Start-Up no: yes: G: Static Switch Commutation Check H: Battery Charging Current Limitation Check ? The difference is probably due to distortion of the mains voltage (the inverter voltage is an almost perfect sinewave) Continue with G Continue with G • COMMUTATION TO THE BYPASS Press the pushbutton on the CPHC16-S pcb for the bypass.
SOLA 4000 - Installation and Initial Start-Up 3 Additional Start-Up Proced. for Multi-Unit Systems 3 ADDITIONAL START-UP PROCED. FOR MULTI-UNIT SYSTEMS 3.1 Start-Up Procedure for Hot -standby Systems Repeat the procedure of section 2 for the second unit in the system (with the first unit off). Ensure that the interconnecting BUS cable is connected according to section 1.9.1 and FIG 1.9.3. J ? no yes • Switch off the inverter at the second unit with PB2 at the top of the ICP pcb.
SOLA 4000 - Installation and Initial Start-Up 3 Additional Start-Up Proced. for Multi-Unit Systems 3.2 Start-Up Procedure for Parallel Systems Repeat the procedure of section 2 individually for all units in the system, with the the other units off. Ensure that the interconnecting BUS cables are connected according to section 1.10.1 and FIG 1.10.3. • Open IRP, IRE, IB and IUG of the last unit checked with the procedure in section 2. K • Ensure that no load is connected to the system output.
SOLA 4000 - Installation and Initial Start-Up 3 Additional Start-Up Proced. for Multi-Unit Systems to the nominal load. Measure the currents at the output of each module on phase T. If this current varies by more than ± 1% for this module, fine adjustment can be made with P1 on the IPR pcb. Check the currents at the output of each module on phase S. These currents must be balanced to within ± 1% by finely adjusting the inverter voltage of phase S (P4 on ICT-2). i.e.
Contents of JUE 401266 SOLA 4000 - Operation Chapters 1 OPERATING MODES 2 1.1 General 2 1.2 Led Indication 3 5 OPERATING INSTRUCTIONS 5.1 5.2 2 3 4 OPERATING MODES STANDALONE UNIT 4 2.1 Normal Operation 4 2.2 Battery Operation 4 2.3 Bypass Operation 5 2.4 Maintenance Bypass Operation 5 2.5 Standby Operation 5 11 Switching On the UPS System/from Maintenance Bypass 11 Switching Off the UPS System/to Maintenance Bypass 13 5.
SOLA 4000 - Operation 1 Operating Modes 1 OPERATING MODES 1.1 General There are four different operating modes of the standard standalone on-line UPS-system (5 for hot-standby and 6 for parallel systems), ensuring uninterrupted power supply of the load under all conditions. Transitions between these operating modes are performed without interruption of the power supply to the load.
SOLA 4000 - Operation 1 Operating Modes 1.2 LED Indication The block diagram of the UPS, with integrated LEDs, allows a quick check of the UPS operating status. LED 1 MAINS PRESENT LED 2 RECTIFIER LED 3 BATTERY SWITCH LED 4 BATTERY DISCHARGING LED 5 BATTERY CHARGING LED 14 BYPASS POWER SUPPLY LED 15 MAINTENANCE BYPASS SWITCH LED 16 INVERTER LED 17 LOAD FED by INVERTER LED 18 LOAD FED by BYPASS POWER SUPPLY LED 19 LOAD IS SUPPLIED LED 27 BATTERY TEST LED 28 E.P.O.
SOLA 4000 - Operation 2 Operating Modes Stand-alone Unit 2 OPERATING MODES STAND-ALONE UNIT 2.1 Normal Operation "Normal Operation" is the standard operating mode of the UPS • Mains power is present. • The rectifier converts ac power to dc power which charges the batteries and feeds the inverter. • The inverter converts this dc power to ac power used to feed the connected load. 2.
SOLA 4000 - Operation 2 Operating Modes Stand-alone Unit 2.3 Bypass Operation The "Bypass Operation" mode is activated by an inverter failure or an overload • The rectifier supplies dc power only to the battery. • The static inverter switch SSI opens automatically after the static bypass switch SSB is closed. • The load is supplied directly from the mains through the static bypass line. 2.
SOLA 4000 - Operation 3 Operating Modes Hot-Standby Operation 3 OPERATING MODES HOT-STANDBY OPERATION 3.1 Normal Operation "Normal Operation" is the standard operating mode of the hotstandby system. • Mains power is present. • The rectifiers of all units convert ac power to dc power which charges the batteries and feeds the inverters. • The inverters convert this dc power to ac power. • The inverter of one unit feeds the connected load.
SOLA 4000 - Operation 3 Operating Modes Hot-Standby Operation • If an additional failure in the first unit occurs, or when the battery of that unit is exhausted, the inverter of another unit will takeover the load, continuing in battery operation until the mains returns or the second battery is exhausted. 3.4 Bypass Operation The "Bypass Operation" mode is activated by an overload or by inverter failures in all units or by a manual commutation. • The rectifiers supply dc power only to the batteries.
SOLA 4000 - Operation 4 Operating Modes Parallel and Parallel/Redundant Operation 4 OPERATING MODES PARALLEL AND PARALLEL/REDUNDANT OPERATION 4.1 Normal Operation "Normal Operation" is the standard operating mode of the UPS if the system load is at its nominal value or the system is programmed in a way that all units remain on-line. Otherwise see section 4.2. • Mains power is present • The rectifiers convert a.c. power to d.c.
SOLA 4000 - Operation 4 Operating Modes Parallel and Parallel/Redundant Operation 4.3 Battery Operation The "Battery Operation" mode is activated by a mains failure or rectifier failure • The rectifiers supply no power • The batteries supply the required d.c. power to the inverters • The inverters supply a.c. power to the load as described in 4.
SOLA 4000 - Operation 4 Operating Modes Parallel and Parallel/Redundant Operation 4.
SOLA 4000 - Operation 5 Operating Instructions 5 OPERATING INSTRUCTIONS 5.1 Switching On the UPS System / from Maintenance Bypass Initial UPS Operating Mode: The UPS is switched off, the load may or may not be supplied by maintenance bypass, IBY and all other power switches are open. Operating Steps: A: • Switch on the external mains supply for the UPS; both the rectifier input and the bypass input when separate supplies are provided.
SOLA 4000 - Operation 5 Operating Instructions Final UPS Operating Mode: The UPS is now in normal operating mode, as described in chapter "2.1. Stand-alone unit", "3.1 Hot standby systems" or "4.1 Parallel systems". The green LEDs (L1, L2, L5, L3, L16, L17, L26, L19) on the operating panel(s) must be illuminated (but not flashing). Should a problem arise during the Switching On, please follow the instructions in JUE 401066, Initial Start-up. Note 1: For Parallel Systems.
SOLA 4000 - Operation 5 Operating Instructions 5.2 Switching Off the UPS System / to Maintenance Bypass Initial UPS Operating Mode: The UPS is in any operating mode described in the previous sections "Operating Modes" (except maintenance bypass operation). All power switches except IBY are closed, and the load is fed either through the inverter or the static bypass. Operating Steps: A: CPHC16-S: IBY IUG: IB: B: • Make sure that the LEDs 14 and 26 "Bypass Power Supply O.K.
SOLA 4000 - Operation 5 Operating Instructions 5.3 Switching On any one unit within a System (Parallel and Hot-standby Systems) Initial UPS Operating Mode The UPS module was switched off using the procedure in section 5.4, all of the power switches in this module are in the off position, the load is supplied by the remaining unit(s) within the system.
SOLA 4000 - Operation 5 Operating Instructions 5.4 Switching Off / any one Unit within a System (Parallel and Hot-standby Systems) Initial UPS Operating Mode: The UPS is in any operating mode described in the previous sections "Operating Modes". All power switches except IBY are closed, and the load is fed either through the inverter or the static bypass. IPR: ICP: S1 • At the bottom of the IPR pcb (if present), switch the microswitch S1 to the manual position.
SOLA 4000 - Operation 5 Operating Instructions 5.5 Emergency Power Off Operating Steps: • To activate the Emergency Power Off, press simultaneously the two pushbuttons in the E.P.O. section of the operating panel (For hot-standby and parallel systems, the operation needs to be performed at one unit only). Attention! This operation will remove all supply to the load. Emergency Shut Down: When E.P.O.
Contents of JUE 401267 SOLA 4000 - Operating Panel Chapters 1 Figures FUNCTIONS 2 1.1 Indication of Important Data 2 FIG. 2.1 LED Indication 5 1.2 Battery Monitoring 2 FIG. 3.1 RS232 connection cable 9 1.3 UPS Operating Mode Indication 3 FIG. 4.3 Layout of the CPU/NCP pcb 16 1.4 Alarm Signalling 3 FIG. 5.1 Setting of DIP1 19 1.5 Remote Monitoring 3 1.6 Emergency Power Off 4 Tables 2 LED INDICATION 5 3 COMMUNICATION WITH A PC 9 TAB 4.
SOLA 4000 - Operating Panel 1 Functions 1 FUNCTIONS 1.1 Indication of Important Data Actual Load Battery Charging Status Battery Autonomy The actual load of the UPS is indicated as a percentage of its nominal load capacity. While the battery is being charged (green LED 5 on), the actual charging status of the battery is indicated as a percentage of the nominal battery capacity.
SOLA 4000 - Operating Panel 1 Functions 1.3 UPS Operating Mode Indication On the operating panel a block diagram of the UPS is shown. The operating mode of the UPS is indicated with LEDs integrated into the block diagram. LED Off LED On, Green LED Flashing, Green LED On, Yellow LED Flashing, Red If a LED is not illuminated at all, the corresponding section is not active. If a LED is continually illuminated (green), the corresponding section is o.k.
SOLA 4000 - Operating Panel 1 Functions 1.6 Emergency Power Off In case of emergency it is possible to switch off the complete UPS system. This is done by simultaneously pressing the "EMERGENCY POWER OFF" (E.P.O.) push-buttons located on the operating panel. This function provides UPS disconnection from the load and galvanically isolates the UPS from the battery.
SOLA 4000 - Operating Panel 2 LED Indication 2 LED INDICATION The block diagram of the UPS, with integrated LEDs, allows a quick check of the UPS operating status. FIG. 2.
SOLA 4000 - Operating Panel 2 LED Indication LED 1 MAINS PRESENT • Green LED is continually illuminated = Mains O.K.(rectifier). • Green LED flashing slowly + BUZZER beeping slowly (approx. every 2 sec.) = Mains is not O.K. LED 2 RECTIFIER • LED off = Rectifier is not supplied • Green LED is continually illuminated = Mains and rectifier O.K. • Red LED flashing fast + BUZZER beeping fast (every sec.
SOLA 4000 - Operating Panel 2 LED Indication LED 18 LOAD FED BY BYPASS POWER SUPPLY • Yellow LED is continually illuminated = Load fed by static bypass • Otherwise LED is off. LED 19 LOAD IS SUPPLIED • Green LED is continually illuminated = Load fed either by inverter or by static bypass and IUG is closed • Otherwise LED is off. LED 27 BATTERY TEST This test is only performed if the batteries are fully charged. Otherwise the test is skipped and performed in the following month.
SOLA 4000 - Operating Panel 2 LED Indication LOAD PERCENTAGE The actual load is indicated by LEDs as a percentage of the nominal load. • All LEDs off => Actual load = 0 - 10% • Green LED 20% cont. illumin. => Actual load = 10 - 30% • Green LED 40% cont. illumin. => Actual load = 30 - 50% • Green LED 60% cont. illumin. => Actual load = 50 - 70% • Green LED 80% cont. illumin. => Actual load = 70 - 90% • Green LED 100% cont. illumin. => Actual load = 90 - 100% • Red LED 125% cont. illumin.
SOLA 4000 - Operating Panel 3 Communication with a PC 3 COMMUNICATION WITH A PC 3.1 Connection to PC The UPS is connected to the PC via the RS232 interface. The respective connector is the female 9-pin sub-D connector on the CPU/ NCP pcb on the inside of the UPS front door. At the PC a serial port is used which can either be a male 9-pin sub-D connector or a male 25-pin sub-D connector. Cable Specification For connecting the PC and UPS use twisted pair, 24 AWG shielded cable.
SOLA 4000 - Operating Panel 3 Communication with a PC 3.2 SNMP MODE With DIP7 of SW2 in the ON position, the UPS can be monitored and controlled from a remote location by a PC through a SNMP protocol converter. In this mode, software packages such as SMARTMON from Systems Enhancement Corporation may be directly applied using a P.C.
SOLA 4000 - Operating Panel 3 Communication with a PC 3.4 Alarms With a connected PC, the following alarms are realised (SNMP and service modes): Rectifier Failure The Rectifier mains is in order but a failure is present within the rectifier. Inverter Failure The inverter is ON but the inverter voltage or inverter conditions are not in order.
SOLA 4000 - Operating Panel 3 Communication with a PC For systems with multiple static bypasses (hot-standby and parallel/redundant), if the bypass of this unit is available, but the bypass system is not available, the UPS system cannot transfer to the bypass supply, due to the fact that there may be insufficient bypasses available within the system. Overload The UPS is overloaded by more than the nominal output load current Load on Bypass The UPS system load is being supplied by the bypass supply.
SOLA 4000 - Operating Panel 3 Communication with a PC 3.5 UPS status Additionally to the above alarms, the following status conditions are realised: Boost Charge The rectifier is re-charging the battery with a boost charge (according to DIN 41773). Output Switch OFF The output switch (IUG) is OFF and the load is not supplied by this unit. Service Bypass ON The load is supplied by any of the maintenance bypass(es). 3.
SOLA 4000 - Operating Panel 4 Panel Settings 4 PANEL SETTINGS 4.1 DIP Switch Settings With the DIP switches SW1 and SW2 on the CPU/NCP pcb inside the front door , the operating parameters can be set according to actual conditions. Note: The following settings apply only with the software V2.0 or later.
SOLA 4000 - Operating Panel 4 Panel Settings DIP Switch SW2 Dip 1 AUDIBLE ALARM OFF Audible alarm ENABLED ON Audible alarm DISABLED Dip 2 AUTONOMY ALARM OFF Autonomy alarm ENABLED ON Autonomy alarm DISABLED Dip 3 BATTERY TEST OFF Battery test DISABLED ON Battery test ENABLED DIP 4 TIME CONSTANT OFF FAST ON NORMAL DIP 5 OFF ON DIP 6 FREQUENCY OFF 60 Hz ON 50 Hz DIP 7 REMOTE ACCESS OFF Service mode ON SNMP mode DIP 8 Forced Battery Test (If DIP3=ON) OFF Forced batt.
SOLA 4000 - Operating Panel 4 Panel Settings 4.2 Location of DIP-switches and pushbuttons on the CPU/NCP pcb The CPU/NCP pcb is located inside the front door at the UPS cubicle. FIG. 4.3Layout of the CPU/NCP pcb PL1 PL2 Microprocessor RESET Emergency Power Off (E.P.O.
SOLA 4000 - Operating Panel 5 Remote Panel 5 REMOTE PANEL 5.1 General The Remote Panel is used for remote monitoring of SOLA 4000 systems for distances of up to 400m. It is connected by cable via a RS485 interface. It can be installed in a control room and provides the same user interface as the local operating panel. Only the E.P.O. function is not implemented. 5.2 Installation The Remote Panel is connected to the UPS by a shielded cable 4x0.5mm of max. 400m length with 9-pole sub-D connectors.
SOLA 4000 - Operating Panel 5 Remote Panel 5.3 Functions General The Remote Panel provides the same LED indications as the SOLA 4000 operating panel. Alarms are indicated by flashing LEDs and an integrated buzzer. The alarms can be muted directly at the Remote Panel by pressing the "Alarm Reset" push-button. The buzzer can be deactivated by setting switch 2 of DIP1 to the Off position. The inverter can be switched on from the remote panel but cannot be switched off.
SOLA 4000 - Operating Panel 5 Remote Panel Communication timing When an alarm condition occurs, the Remote Panel calls the first programmed number. If the line is busy and only one number is to be called, the Remote Panel waits for 5 minutes and, if the alarm condition is still present, it tries to call the number again. This procedure will be repeated until the connection has been established or the alarm condition ends.
Contents of JUE 401268 SOLA 4000 - PCB Description Chapters 1 Figures UPS CONTROL LOGIC 2 1.0 UPS Control Logic 2 FIG. 1.1 - IF/PS - R front view 3 1.1 Legend of symbols used 2 FIG. 1.2 - CPHC16 - R front view 4 1.2 Rectifier 3 FIG. 1.3 - ICP front view 6 1.3 Inverter 5 FIG. 1.4 - ICT-2 front view 7 1.4 Bypass 10 FIG. 1.5 - IPS-500 front view 8 FIG. 1.6 - IPR front view 9 FIG. 1.7 - IF/PS - S front view 11 FIG. 1.
SOLA 4000 - PCB Description 1 UPS Control Logic 1 UPS CONTROL LOGIC 1.0 UPS Control Logic The UPS Control logic is situated in the centre of the front part of the UPS. It consists of one rack with 7-8 PCBs (depending on the system configuration). On the covers of the rack, the various potentiometers, test points and LEDs are briefly labelled. A more detailed explanation is given in this chapter. 1.1 Legend of symbols used LED (light emitting diode) - GREEN: normal condition - RED: alarm condition.
SOLA 4000 - PCB Description 1 UPS Control Logic 1.2 Rectifier The rectifier control logic consists of two PCBs.
SOLA 4000 - PCB Description 1 UPS Control Logic CPHC16 - R Front View FIG. 1.2 illustrates the display, switches and connectors of the CPHC16 - R PCB which are accessible from the front. - 7 segment display for diagnostics (see table below) DIAGNOSTICS RESET MAX. Vdc - Reset max. Vdc pushbutton: press when the character "4" is displayed or the central segment is blinking. - Reset Boost Charge Alarm - Reset after EPO (V2.
SOLA 4000 - PCB Description 1 UPS Control Logic In normal condition the display shows a red segment rotating clockwise. During the starting phase, a blinking central segment "-" is displayed. During parameter acquisition through the serial interface, the character "A" is displayed. If more than one alarm is present, only the one with the higher priority is displayed. 1.3 Inverter The inverter control logic consists of three PCBs (four for parallel systems).
SOLA 4000 - PCB Description 1 UPS Control Logic PB2 Inv. ON / OFF Inverter control and regulation (parallel configuration) • parallel regulation of up to 8 inverters • system control for up to 8 inverters (together with ICP pcb) • cold-standby control • load monitoring • redundancy monitoring LD1 PSP OK ICP Front View LD3 Osc. Failure PB1 Reset LD9 Inverter OK LD8 Inverter volts OK LD2 Retr. blocked FIG. 1.3 illustrates the LEDs and switches of the ICP PCB which are accessible from the front.
SOLA 4000 - PCB Description 1 UPS Control Logic - Proportional to the inv. voltage. 6V ≡ nominal inverter voltage - Inv. voltage tolerance adjust for 6V at TP1 with nom. voltage - Push to switch ON the inverter output static switch (SSI) P1 Freq. Offset P5 ΦT Volts View ICT-2 Front P4 ΦS Volts FIG. 1.4 illustrates the potentiometers, LEDs and test points of the ICT-2 PCB which are accessible from the front.
SOLA 4000 - PCB Description 1 UPS Control Logic IPS-500 Front View FIG. 1.5 illustrates the potentiometers, LEDs and test points of the IPS-500 which are accessible from the front. - Test point: test voltage = 4Vdc at full load on phase R LAS Power - ON - Current limitation adjustment phase T. Adjust for 4Vdc at TP3 DF1 Power Supply OK - Current limitation adjustment phase S. Adjust for 4Vdc at TP2 - Current limitation adjustment phase R.
SOLA 4000 - PCB Description 1 UPS Control Logic IPR front view FIG. 1.6 illustrates the LEDs, potentiometers, switches and test sleeves of the IPR pcb that are accessible from the front. LD1 Parall.Operat LD2 Red not ok - Parallel Operation On: This inverter is connected with another or more inverters to the output in parallel. - Redundancy Not OK: Redundant units only.The load has increased or an inverter is off so that if this unit fails, the system must transfer to the bypass supply.
SOLA 4000 - PCB Description 1 UPS Control Logic 1.4 Bypass The bypass static switch control logic consists of two PCBs.
SOLA 4000 - PCB Description 1 UPS Control Logic IF/PS - S Front View PSPA PSPP FIG. 1.7 illustrates the LEDs of the IF/PS - S PCB which are accessible from the front.
SOLA 4000 - PCB Description 1 UPS Control Logic CPHC16 - S Front View FIG. 1.8 illustrates the display, switches and connectors of the CPHC16 - S PCB which are accessible from the front.
Contents of JUE 401269 SOLA 4000 - Technical Data Figures 1 2 3 4 SYSTEM DATA 2 FIG. 1.1 - System Data 2 RECTIFIER DATA 3 FIG. 2.1 - Rectifier Data 3 BATTERY DATA 4 FIG. 3.1 - Battery Data 4 INVERTER DATA 5 FIG. 4.1 - Inverter Data 5 We reserve the right to modify the contents of this document without notice. BEST POWER- BORRI ELETTRONICA INDUSTRIALE S.r.l Via 8 Marzo Soci, Bibbiena (AREZZO) ISSUED A See Rev. Doc. JSE 401440 04.02.97 20.06.97 M. Porpora T. Boon 04.02.
SOLA 4000 - Technical Data 1 System Data Type SOLA 4000 Technical Data / System Data 10 15 20 30 40 60 System configuration On-line (double conversion) Nominal input voltage 3Ph+N x 380 ÷ 415 V Tolerance: ± 10% Nominal input frequency 50 / 60 Hz Tolerance: ± 10% Nominal output voltage 380 / 400 / 415 Vac (adjustable) Nominal output frequency 50 / 60 Hz Output voltage distortion (THD) linear load non linear load at 100% of Pn and C.F.
SOLA 4000 - Technical Data 2 Rectifier Data Type SOLA 4000 Technical Data / Rectifier Data 10 15 20 30 40 60 80 100 120 Input voltage Tolerance with reduced output (DC) voltage refer to system data refer to system data -20 % Input frequency Tolerance refer to system data ± 10 % Rated input power with charged battery [kVA] 10,8 16 21,3 32 42,7 64,1 84,8 106 127,4 Rated input current with charged battery (380 V) [A] 16,4 24,6 32,7 49,2 65 97,5 128,5 160,7 193 Maximum input p
SOLA 4000 - Technical Data 3 Battery Data Charger input voltage 10 15 20 Technical Data / Battery Data 2,25 V/Cell [VDC] 2,25 V/Cell [VDC] 1,42 V/Cell [VDC] Boost charge voltage Lead-Acid open 2,4 V/Cell [VDC] Ni-Cd 1,54 V/Cell*** [VDC] Lead-Acid maintenance free (no boost charge) Minimum battery voltage Lead-Acid 1,69 V/Cell 40 60 80 100 [VDC] 3 x 380 V 3 x 400 V 3 x 415 V 192 192 300 192 192 300 192 192 300 432 432 426 432 432 426 432 432 426 462 462 462 462 462 462 325 325 325
SOLA 4000 - Technical Data 4 Inverter Data Type SOLA 4000 Technical Data / Inverter Data 10 15 20 30 Permissible input DC voltage range Input power at rated load - 40 60 80 100 120 320 - 480 V/DC [kW] 8,7 13 12,4 26 35,1 70,3 87,9 105,5 27 40 54 80 107,5 161,2 212,5 266 319 15,2 22,7 30,3 45,5 60,8 91,3 Nominal output current (380V, cos phi = 1,0) [A] 12,1 18,1 24,2 36,4 48,6 73 97,4 122 146 Efficiency at 80% load - > 92 > 92 > 92 > 92 > 92 > 93 > 93 > 93
