Tycor-UPS Ty-Borealis Series Operator'S Manual Download Page 13 | Manualshive

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2.1

General Topology

Figure 2.1

General Block Diagram

ELI Module Components:

components:

The ELI module consists of the following major

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Input, Reserve and Bypass circuit breakers
Rectifier / Charger
Inverter
Microprocessor controlled logic and control panel with alarm indicators and digital
metering display
External battery connection
Static bypass
Full maintenance bypass
Emergency power off (EPO) connection
Communications interface
SNMP Adapter for network communications and monitoring
Input power walk-in
Front cable connections
Output isolation transformer
Optional Features:

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12-pulse rectifier and harmonic filter to reduce input harmonic content.
Additional battery modules for extended runtime
Top cable entry
Remote display panel
Emergency power off switch
External maintenance bypass cabinet
Isolated parallel redundant operation (IPRO)

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Generally, there are four modes of operation for an ELI system, NORMAL MODE,
BACK-UP (BATTERY) MODE, RESERVE MODE and MAINTENANCE BYPASS
MODE.

3

2 Theory of Operation

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

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Summary of Contents for Ty-Borealis Series

Page 1: ...Ty Borealis Series Three Phase ELI System 8 KW 48 KW Operators Manual M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 2: ...i M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 3: ...contained in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred directly to Tycor UPS A...

Page 4: ...ocedures contained in this manual please contact our Service Centre before proceeding This document may not be copied or reproduced without the explicit written permission of Tycor UPS Due to technical advancements and improvements some of the information contained in this manual may be changed or modified without prior notice iii WARNING This manual is intended to provide installation instruction...

Page 5: ...king any other connection to the equipment A terminal to from which an alternating current or voltage may be applied supplied A terminal to from which a direct current or voltage may be applied supplied This symbol indicates the word phase iv This symbol indicates an electrical hazard may be present This symbol alerts you to important information M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013...

Page 6: ...UPS may cause an unsafe condition WARNING RISK OF ELECTRICAL SHOCK use extreme caution when removing covers All maintenance and service work should be performed by qualified and trained service personnel The ELI may contain its own energy source batteries which can be dangerous to the untrained person This ELI contains potentially hazardous voltages The field wiring terminals may be electrically l...

Page 7: ...on free of contaminants Storage temperature must be within 25 C 13 F to 55 C 131 F If the unit is stored for a period exceeding 3 months the batteries must be recharged periodically time depending on storage temperature WARNING LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT IS APPARENTLY NOT OPERATING OBSERVE ALL CAUTIONS AND WARNINGS IN THIS MANUAL FAILURE TO DO SO COULD RESULT IN S...

Page 8: ...gnosing problems that may arise Tycor UPS does not assume responsibility if information causes injuries Apart from the front door do not open any other part of the ELI without consulting the factory first Before removing the protection screens be sure that the unit is completely powered off Be aware that dangerous voltage can be supplied by the internal battery or electrolytic capacitors When syst...

Page 9: ...ronmental Conditions 16 Cable Selection 18 Terminal Strip Connections 19 6 7 Front Panel 20 Operation 25 7 1 7 2 7 3 7 4 7 5 7 6 Switch On Procedure Authorized Trained Personnel Only 25 Shutdown Procedure 26 From Inverter To Manual Bypass Procedure 27 From Manual Bypass to Inverter Procedure 28 Manual Battery Test 28 Battery Condition Test 28 8 The LCD Display 29 8 1 8 2 8 3 8 4 8 5 Menu 0 Main Me...

Page 10: ...ncy Lighting Notification 38 10 Battery Backup Units BBU 39 10 1 Run Time Charts 41 10 2 BBU Configurations 43 Options 45 11 11 1 11 2 11 3 11 4 11 5 Emergency Stop Switch 45 Remote Display Panel 45 12 Pulse Rectifier 45 External Wrap Around Bypass 45 Normally Off Function 45 12 13 Technical Specifications 46 Contact Information 50 ix M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 11: ... with the current mode of operation the LCD screen displays critical system information including Percent Load Remaining battery capacity battery voltage Input voltage Output voltage Input frequency Output frequency and Internal ELI temperature A manual test switch has been incorporated into the input test breaker that makes testing a simple procedure The internal bypass switch allows maintenance ...

Page 12: ... to the critical loads Static Bypass Switch Contained in the ELI module Responsible for automatically transferring the attached load without interruption from the inverter AC output to the bypass AC power source in the event of an overload or degradation of the inverter s performance Maintenance Bypass Switch Contained in the ELI module Used to transferring the attached load without interruption f...

Page 13: ...ce SNMP Adapter for network communications and monitoring Input power walk in Front cable connections Output isolation transformer Optional Features 12 pulse rectifier and harmonic filter to reduce input harmonic content Additional battery modules for extended runtime Top cable entry Remote display panel Emergency power off switch External maintenance bypass cabinet Isolated parallel redundant ope...

Page 14: ...frequency range Backup Mode 2 3 Figure 2 3 Back up Mode Operation As the batteries are connected to the DC bus they supply energy to the inverter via this DC bus the AC power will remain constant and continuous without interruption to the loads when the AC fails or falls out side of the operating parameters Upon return of the supplied AC input power the ELI The rectifier will automatically assume ...

Page 15: ...e without interruption of the AC output Manual Bypass Mode 2 5 Figure 2 5 Manual Bypass Mode Operation During ELI service procedures or battery replacement the loads cannot be interrupted and as such the technician needs to turn off the inverter switch close the bypass breaker and then open the rectifier and reserve utility breakers The ELI is now running in Manual By pass mode supplying utility A...

Page 16: ...ed Gate Bi polar Transistors IGBT A PWM wave synchronized to the bypass input triggers the IGBT s which invert the DC into AC power required by the loads This design decreases the number of required components increases reliability and performance while decreasing acoustic noise size and weight f True galvanic isolation The isolation transformer addresses ground differentials between the input and...

Page 17: ...e ELI monthly test When an abnormal condition low charge rating or bad battery is found the user will be informed immediately through alarms on the ELI system o Charging rate The charging rate is selectable L M H according to Ah ratings of the batteries The charger is designed to charge the larger battery banks without adding an additional charger up to 8hr back up p MTBF of cooling fans Long cycl...

Page 18: ...ure 2 6 Rectifier Function The rectifier design used in the 8KW to 48KW ELI s include a 6 pulse full controlled rectifier Power Factor Correction PFC has been added to maintain a high input power factor independent of the load power factor This 6 pulse rectifier smoothes the current waveform and reduces the harmonic content reflected back to the utility The control circuit regulates the DC bus to ...

Page 19: ...ected The system is designed to incorporate an independent inverter per phase These inverters are totally independent of each other preventing the possibility of cascading failures This allows the user to connect loads to adjacent inverters without affecting the other inverters providing high end voltage regulation under a 100 unbalanced load situation The IGBT is operated in its optimal condition...

Page 20: ...ve path if the overload continues for the specified length of time The load will be operational but in the event of a utility failure the inverter has been shutdown therefore no battery time is available until the overload is removed and inverter is allowed to reset The static switch will only be activated if the input levels are within parameters to ensure the load is only supplied with acceptabl...

Page 21: ...nnot be turned on when the maintenance bypass breaker is in the closed position The operation of the manual bypass breaker is explained later in this manual 11 M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 22: ...ier Driver Rectifier Control Controller Batt Relay R Phase Inverter Driver 6 Pulse Rectifier S Phase Inverter Driver Display LCD Call Service Remote Control Panel T Phase Inverter Switch PC Communications LED SNMP Web Monitoring Dry Contact Battery Monitoring Optional Communication 3 Inter PCB Diagram M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 23: ... 1 477 kg sq m 303 lbs sq ft 40 559mm 22 815mm 32 0 1 600mm 63 0 710kg 1 565lbs 1 614 kg sq m 330 lbs sq ft 48 1 100mm 43 25 815mm 32 0 1 600mm 63 0 920kg 2 024lbs 1 672 kg sq m 207 lbs sq ft WARNING Da nge ro us AC DCPHI G H VOLT AGE INPUT RECT IFIER RESERVE BY P AS S Op erating Proc ed ure Wa rn ing Fo r In stalla tion First Startup Proc edure 1 Close the INPUTbrea ke r P2 Close the RESERVE brea...

Page 24: ...T 1 C N A1 C N A5 C N B 5 C N B 6 R EC T I FI R G L TO R EC M O D U 3C ER C O N T R G 3B PO W ER SU PPL G R Y W AR NI N G LED PAN E L S W ITC H E S LC D PAN EL STATU S LED PAN E L BEEPER R M IM IC PAN EL C N B6 R R R R TO S S M O DU LE 3A M AIN C O N TR O L R G R 3R C O M M U N IC A TIO N S IN TERFA C E TER FAC E C N T2 3T IN VER TER PH ASE C O N TR O L R PH ASE C N T2 3T IN VER TER PH ASE CO N TR...

Page 25: ...559mm 22 Figure 4 5 Front Side Top Views of the System 15 1600mm 63 95mm 3 3 4 815mm 32 M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 26: ...Usually the life expectancy of the ELI is 8 to 10 years The optimal life expectancy of the ELI can be achieved by careful consideration of the site and environment The following precautions and recommendations should be checked when considering the site and environment for the ELI a The ELI should be located in a place with adequate ventilation refer to the specification of the heat dissipation of...

Page 27: ...of 0 C 32 F to 40 C 104 F For optimal performance and reliability the recommended environment temperature is best at 25 C with humidity 0 to 95 non condensing g The floor loading capacity should be sufficient to endure the weight of the ELI Four right angled steel feet attached restrainers are included with the ELI system which should be inserted into the floor for securing the ELI system when the...

Page 28: ...bling of the ELI system has to be sized according to the ELI power rating Sizing of circuit breakers fuses and cables for input utility output load and battery must meet the requirements of local and national electrical codes Refer to Section 10 for technical specifications 18 WARNING Inadequate cable size and over sized breakers can increase the risk of fire or damage connection cables and intern...

Page 29: ... E GRE EN 3 PHAS EINPUT 3 PHAS EOUT PUT T ERMINAL WIT H S INGLES OURCE FIREALARM CONNECT ION ELI OUT PUT BAT T ERY INPUT RECT IFIER RES ERVE INPUT 3 PHAS EINPUT 3 PHAS EOUT PUT T ERMINAL WIT H S INGLE S OURCE 19 IN IR IS IT OR OS OT B ON B G CAUTION REMOVE THE NEUTRAL BONDING JUMPER IF ELI IS CONNECTED TO AN EXTERNAL BYPASS SYSTEM IN IR IS IT OR OS OT B ON B G M4102 Ty Borealis 8 48KW Operators Ma...

Page 30: ...zer can also be set through this LCD The LCD is back lit by LED s for a sharper display but in order to lengthen the LED s life time the LED will automatically shut off 3 minutes after a key has been pressed and will light up again when one of the up down enter keys are pushed 20 WAR NING S T AT US BY P ASS INVERT ER ON R ES ER VE RECTAC FAIL HIGH DC INVST AT IC R ES ER VE OUT PUT S HORTCIR CU IT ...

Page 31: ...ill not activate until the DC voltage is above this level FAULT the inverter has shutdown because an abnormal condition has occurred Possible conditions include overload short circuit high DC shutdown fuse over temperature bypass breaker on or emergency stop refer to C Status LED s C Status LED s 24 LED s represent the real time information regarding the status of the ELI system These LED s will a...

Page 32: ...Y LOW SHUTDOWN the inverter has shutdown because the DC bus or battery voltage is below operating level lower than 295VDC RECTIFIER AC FAIL supply to rectifier is outside of operating window Ø ROTATION ERROR supply phase rotation is outside of operating window RECTIFIER SHUTDOWN the rectifier has shutdown because the DC bus voltage has exceeded maximum operating level over 445VDC The rectifier wil...

Page 33: ...llow for the user to be sure the operation was performed correctly E Bypass LED This LED is lit when the maintenance bypass breaker is closed leaving the inverter in the off mode If the inverter is active when the bypass breaker is closed the inverter will shutdown immediately F Reserve LED This LED is lit when the reserve breaker is closed and the supply is within operating parameters G Rectifier...

Page 34: ...orward when data or parameters of the ELI are being set N Down key This is an LCD control key It moves the cursor one field downward when items are being selected or changes the number character backward when data or parameters of the ELI are being set O Enter key This is an LCD control key It returns to the previous page and also confirms the number character item selected P Inverter On Switch Th...

Page 35: ...The rectifier will automatically start if the AC utility power connected is within operating parameters The DC voltage will slowly rise 15 30 sec until the designated voltage is reached The DC voltage is now ready for the inverter and battery bank d Close the battery breaker holder A breaker between the battery bank and the ELI is used for safety purposes The batteries will start charging once the...

Page 36: ... bus will start to drop slowly until it reaches a save level of approximately 20VDC d Open the reserve breaker Before opening the reserve breaker you must make sure there is no critical load connected to the ELI that requires power NO OUTPUT POWER WILL BE SUPPLIED FROM THE ELI ONCE THE RESERVE UTILITY BREAKER IS OPENED 26 WARNING Completing the next step will turn off the power to the loads Make s...

Page 37: ...us therefore the DC bus will start to drop slowly After 5 min the DC bus will drop to a safe level approx 20VDC d Close the bypass breaker The reserve breaker and reserve static switch are still conducting When the maintenance bypass breaker is closed power will flow through the bypass loop instead of the reserve loop because the impedance of the bypass loop is lower e Open the reserve breaker You...

Page 38: ...ating parameters The DC voltage will slowly rise 15 30 sec until the designated voltage is reached The DC voltage is now ready for the inverter and battery cabinets g Close the battery breaker A fuse holder is employed from the battery to the DC bus for safety purposes The batteries will start charging once the breaker is closed The breaker can be located within the battery cabinets h Push inverte...

Page 39: ...g of the UPS The serial no is set by the factory for the convenience of maintenance personnel who may need to refer to the serial number for the correct spare parts and testing procedures The identification no is set only when multiple UPS systems are connected in parallel Each UPS must have a unique number to identify itself and will be set by a factory trained technician after installation The Y...

Page 40: ... shows the real time status of the rectifier inverter and static switch while the right hand side shows the warning or fault condition if any Under normal condition the LCD display should be exactly the same as the figure shown above When abnormal conditions occur it will be shown under the title WARNING but this will be overridden by a fault message if more serious abnormal conditions occur and t...

Page 41: ... system 110 OVERLOAD over 110 maximum capacity for the ELI system 3rd row BATTERY LOW STOP Battery have been exhausted BATTERY LOW Batteries have passed the low voltage level and will soon be exhausted BATTERY BAD One or more cells have tested faulty BATTERY GND FAULT Battery cabinet not grounded properly BATTERY TESTING performing test on the batteries Listed below are all the fault conditions th...

Page 42: ...s reached by selecting RECTIFIER DATA on MENU 3 The information provided on this menu is the real time readings of the rectifier input RECTIFIER FREQUENCY R N S N T N VOLTAGE for wye Y configured systems or R S S T T R VOLTAGE on delta configured systems The UP or DOWN key has no function in this menu The screen will return to MENU 3 when the ENTER key is pressed Reserve Data Menu Figure 8 7 Reser...

Page 43: ...configured systems or R S S T T R VOLTAGE on delta configured systems The UP or DOWN key has no function in this menu The screen will return to MENU 3 when the ENTER key is pressed Other Data Menu Figure 8 9 Other Data Menu Display This menu is reached by selecting OTHER DATA on MENU 3 The information provided on this menu is the real time readings of the ELI system TEMPERATURE DC VOLTAGE CHARGE O...

Page 44: ...ace back that occurrence A maximum of 77 records can be stored in one EEPROM This can be increased to 154 records with the addition of a second EEPROM These records are hard coded onto the EEPROM and will not be erased by cutting off the power supply or during a complete shutdown of the ELI i e they will be kept in the EEPROM forever until they re overwritten by the 78th or the 155th events The th...

Page 45: ... BYPASS ON SHUTDOWN The display in the top right corner of the screen is the ELI installation time displayed in year month This information is provided to allow the user or the maintenance personnel to have a reference point to schedule the next preventative maintenance visit To return to MENU 1 press the ENTER key 35 M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 46: ...rgency stop inverter abnormal and bypass on shutdown The contact is latched until it is manually reset off switch or the fault has been cleared for 30 seconds SS Short when the inverter is supplying output power open when reserve is supplying output power The two output will never conduct simultaneously BYPASS Short when the maintenance bypass breaker is closed open when the breaker is opened BACK...

Page 47: ...wer off Connection One pair of terminals CNR 3 are provided to allow the user to shutdown the ELI system in an emergency situation e g fire short circuit etc A minimum of 10mA is needed for activate the photo coupler 9 4 DB9 Connectors One RS 485 and one RS 232 are provided to communicate with more sophisticated optional communication modules Each connector is dedicated to one type of external mod...

Page 48: ... overload condition Inverter failure due to a b c d e f g Rectifier DC output to high Output short circuit Inverter fuse open or over temperature condition Inverter overload condition Emergency stop activation Inverter output outside or parameters Bypass activated inverter shutdown 3 4 5 6 Manual bypass activation Utility AC failure on battery Battery low condition No Output Voltage Present 38 M41...

Page 49: ... to strengthen the cabinet for the additional weight and transportation Banks contain the batteries and provide the runtime for the ELI system The Battery Physicals for 3 Ø Battery Cabinet 3 Ø Width 1321mm Depth 864mm and Height 1930mm Figure 10 1 3 Phase Battery Cabinet Layout 39 10 Battery Backup Units BBU M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 50: ... removed prior to BBU installation completely shut down ELI wait for 30 minutes until capacitors have fully discharged and disconnect ELI from BBU prior to servicing Figure 10 2 Slide out BBU shelves 40 CAUTION Only qualified service personnel should attempt battery bank maintenance Removal of the side access panels exposes personnel to potential dangerous voltages and shock hazards that may cause...

Page 51: ...A A A A B B B Estimated System Weight lb kg 3 036 1 380 3 562 1 619 4 066 1 848 5 157 2 344 7 581 3 446 9 324 4 238 9 632 4 378 Standard Battery Systems for 30 minute runtime Type R Battery Maintenance Free Sealed Lead Acid 10 Year Design Life Expectancy System Capacity Rating 8kW 12kW 16kW 24kW 32kW 40kW 48kW ELI Dimensions WxDxH in 22 x 32 x 63 22 x 32 x 63 22 x 32 x 63 22 x 32 x 63 22 x 32 x 63...

Page 52: ... 22 x 32 x 63 22 x 32 x 63 22 x 32 x 63 22 x 32 x 63 22 x 32 x 63 22 x 32 x 63 ELI Dimensions WxDxH mm 550 x 812 x 1 600 550 x 812 x 1 600 550 x 812 x 1 600 550 x 812 x 1 600 550 x 812 x 1 600 550 x 812 x 1 600 550 x 812 x 1 600 BBU Dimensions WxDxH in 52 x 34 x 76 52 x 34 x 76 52 x 34 x 76 2 52 x 34 x 76 2 52 x 34 x 76 3 52 x 34 x 76 3 52 x 34 x 76 BBU Dimensions WxDxH mm 1 315 x 850 x 1 930 1 31...

Page 53: ...10 2 BBU Configurations Figure 10 3 Configuration A Figure 10 4 Configuration B 43 M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 54: ...Figure 10 5 Configuration C 44 M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 55: ...s via a DB9 connected in series from distance 1000m It allows for remote monitoring of the ELI status and alarms 11 3 12 Pulse Rectifier Located inside the ELI system cabinet The 12 pulse rectifier is an optional feature for 8KW to 48KW systems The 12 pulse rectifier is designed to reduce the input harmonic distortion to less than 2 11 4 External Wrap Around Bypass A separate cabinet that allows f...

Page 56: ...208V 480V 600V 3 phase 3 and 4 wire G Input Range 180 750V Input Frequency 50 60 Hz 7 Input Power Factor 1 Normal Input Current A Based 208VAC on 33 49 66 99 132 165 198 Maximum Input Current A Based 208VAC on 45 63 83 125 160 200 250 Current THD 6 PULSE 30 12 PULSE 15 12 PULSE WITH FILTER 9 Power Walk In adjustable 0 100 20 sec Efficiency 99 Voltage Regulation 1 Ripple Voltage 0 5 KW Rating 8 12 ...

Page 57: ...tage Regulation 100 Unbalance Load 1 Frequency Lock Range 45 55 Hz 55 65 Hz Output Frequency Free Running 50 60 Hz 0 1 Hz Output Voltage Tolerance Static 1 Load step 0 100 0 3 recovering to within 1 in 1 cycle Load step 0 50 0 2 recovering to within 1 in 1 cycle 100 unbalanced load Ph N 2 5 Phase Shift Under 100 Unbalance Load 120 0 5 THD Linear Load 2 Overload 110 CONTINUOUS 110 125 15 min 125 15...

Page 58: ...6 3 3 5 Weight kg 250 275 300 400 480 550 680 Dimension HEIGHT mm 1600 WIDTH mm 559 DEPTH mm 815 Audible Noise 65 dBA AT 1 m Standards CSA Yes CE Yes EN50091 1 2 Yes FCC Part 15 Class A Yes Protections Short Circuit Rectifier Reserve Bypass NFB Lightning MOV EMC Filter Input Output Galvanic Isolation Between Input Output Data Display By LCD Yes Indications Alarms LED LCD Buzzer Yes Dry Contact Yes...

Page 59: ...30A 480 277V 40A 480 277V 60A 480 277V 80A 480 277V 100A 480 277V 125A 600 347V 15A 600 347V 30A 600 347V 30A 600 347V 50A 600 347V 60A 600 347V 80A 600 347V 90A Output Voltage and Maximum Output Current in Amperes 208 120V 22 3A 480 277V 9 7A 208 120V 33 4A 480 277V 14 5A 208 120V 44 5A 480 277V 19 3A 208 120V 66 7A 480 277V 28 9A 208 120V 88 9A 480 277V 38 5A 208 120V 111 1A 480 277V 48 2A 208 1...

Page 60: ... Contact Information Tycor UPS Systems Inc Website www tycorups com Email sales tycorups com Phone 250 765 8448 2646 Dry Valley Rd Kelowna BC V1V 2K1 M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

Page 61: ...51 52 M4102 Ty Borealis 8 48KW Operators Manual v1 0 2013 08 14 ...

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