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Project: 2.

2 MTPA DHDT PLANT - VADODARA REFINERY


Customer: INDIAN OIL CORPORATION LTD

P.O.: FAO 3293/2007 &


3293/2007/18008326
DUAL UPS Apodys 70kVA
400VDC 1x110V

Chloride ref: 318107


Project ID: 080930 / 05
Installation, Operation and Maintenance manual OF: W015939
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 7 

1.1. GENERAL 7 

1.2. NATURE OF HAZARD 8 

1.3. SAFETY PRECAUTIONS 8 

1.4. EMERGENCY ACTION AND TREATMENT 9 

1.5. BATTERY 9 

1.6. COSHH STATEMENT 11 

2. DESCRIPTION AND OPERATION 14 

2.1. DESCRIPTION 14 

2.2. TOPOLOGY 14 

2.3. OPERATING MODES 17 

3. SYSTEM SPECIFICATION 22 

3.1. CHARACTERISTICS 22 

4. INSTALLATION 23 

4.1. HANDLING ON ARRIVAL 23 

4.2. STORAGE 24 

4.3. PUTTING INTO INSTALLED POSITION 24 

4.4. ELECTROLYTE / CELL OIL 25 


4.4.1. Cells delivered filled 25 
4.4.2. Cells delivered empty 25 

4.5. CABLE ENTRIES 25 

4.6. TERMINAL CONNECTIONS 25 


4.6.1. Phase rotation 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 

4.8. BATTERY-VENTED CADMIUM NICKEL 26 

4.9. BATTERY INSTALLATION 26 

5. OPERATING INSTRUCTIONS 28 

5.1. LIGHT EMITTING DIODES (LEDS) 29 

5.2. DISPLAY 30 

5.3. CONTROL PUSH-BUTTONS 31 

5.4. PRESENTATION OF THE MENUS 32 

5.5. GENERAL MENU 32 

5.6. UPS BLOCK MENUS 33 

5.7. CONTROL PANEL MENUS 36 

5.8. CHANGE CHARGER MODE 41 

5.9. MEASURES, FAULTS AND WARNINGS 42 

5.10. HEADING 42 

5.11. RECTIFIER/CHARGER INFORMATION 45 

5.12. BATTERY INFORMATION 46 

5.13. INVERTER INFORMATION 46 

5.14. RESERVE INFORMATION 47 

5.15. LOAD AND STATIC SWITCH INFORMATION 47 

5.16. OPERATING INSTRUCTIONS 48 


5.16.1. First start-up 48 
5.16.2. Maintenance procedure 50 
5.16.3. Transfer to maintenance for a stand-alone inverter 52 
5.16.4. Return from maintenance for a stand-alone inverter 52 
5.16.5. Global maintenance procedure 53 
5.16.6. Black start procedure 53 

6. ROUTINE MAINTENANCE 54 

6.1. GENERAL 54 

6.2. ONCE A WEEK 54 

6.3. ONCE A MONTH 54 

6.4. AT LEAST 4 TIMES PER YEAR 55 

Page 4 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

6.5. ANNUALLY 55 

6.6. FANS 55 

7. FAULT DIAGNOSIS 56 

7.1. CHARGER DISPLAY MENU 57 

7.2. CHARGER DEFAULTS 58 

7.3. CHARGER VOLUNTARY STOPPED 59 

7.4. CHARGER WARNING 59 

7.5. BATTERY FAULT 60 

7.6. BATTERY WARNING 60 

7.7. INVERTER DISPLAY MENU 61 

7.8. INVERTER FAULTS 62 

7.9. INVERTER VOLUNTARY STOPPED 63 

7.10. INVERTER WARNING 63 

7.11. RESERVE WARNING 64 

7.12. AC LOAD/ STATIC SWITCH FAULT 64 

7.13. AC LOAD/STATIC SWITCH WARNING 65 

8. SPARE PARTS 66 

8.1. GENERAL NOTES 66 

9. DRAWINGS 67 

9.1. GENERAL NOTES 67 

10. ATTACHMENTS 68 

10.1. BATTERY MANUAL 68 

Page 5 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

LIST OF ILLUSTRATIONS

Title Page

Figure 2.1 : Block Diagram 14 

Figure 2.2 : Voltage Current Characteristic of Charger 15 

Figure 2.3 : Normal Mode 17 

Figure 2.4 : Primary AC Supply Fail Mode 18 

Figure 2.5 : DC Alarms During Primary Supply Failure 18 

Figure 2.6 : Reserve to Load 19 

Figure 2.7 : Maintenance Bypass Mode 20 

Figure 2.8 : One UPS Fail 21 

Page 6 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

1. SAFETY

Title Page

1.1. GENERAL 7

1.2. NATURE OF HAZARD 8

1.3. SAFETY PRECAUTIONS 8

1.4. EMERGENCY ACTION AND TREATMENT 9

1.5. BATTERY 9

1.6. COSHH STATEMENT 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 A note in this style is used to emphasise an important point in the text

CAUTION : USED TO PREVENT DAMAGE TO EQUIPMENT

WARNING : A WARNING IS USED TO ALERT PERSONNEL TO


HAZARDS TO PERSONAL SAFETY.

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

Page 7 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

1.2. NATURE OF HAZARD

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

BATTERY ELECTROLYTE in ALL batteries is dangerous and can cause severe burns if
allowed to come into contact with the skin or eyes. It will also attack clothing and some paint
finishes and metals. NICKEL CADMIUM batteries contain potassium hydroxide (Caustic
Potash) solution.
HYDROGEN and OXYGEN are given off at the cell plates during charging and can be
present at other times, particularly if cells are moved or shaken. Hydrogen in conjunction with
air or oxygen can be explosive in the presence of sparks or flame.
In sealed cells the amount of gas produced is reduced by the use of restricted charging
techniques. If sealed cells are over charged hydrogen and oxygen will be released to the air
via the pressure vent.
Battery cells or cellblocks can be very heavy and often have to be moved to positions with
difficult access. When working on batteries with many cells or blocks, muscle strain may
occur suddenly or after battery installation is complete. The immediate results and long term
effects can be dangerous and painful.

1.3. SAFETY PRECAUTIONS

Use only insulated tools, particularly when connecting a battery. Stand on a rubber mat.
Personal effects of metal such as rings, watches, bracelets and necklaces which may cause a
short circuit and metal objects (pens, tools etc) which may fall from open pockets while
bending over batteries or chargers should be removed.
Transfer to MAINTENANCE MODE (See Section 5) before working on the equipment.
If it is necessary to make adjustments with the equipment connected to the AC supply and/or
the battery, remove only those protective covers which are absolutely necessary for access.
Always use eye protection and rubber gloves when handling cells. Handle cells with care,
ensuring they are kept upright.
Use properly constructed staging or platforms as a resting-place close to the final position and
enlist assistance with large cells or large numbers of cells. Keep the back straight and upright
when lifting cells. Use only proper lifting techniques.
Do not smoke. Do not use open flames. Avoid creating an arc or sparks when working on this
equipment. Avoid wearing clothing which is susceptible to discharge of static electricity.
After work is complete, refit all protective covers and close and lock all doors.

Page 8 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

1.4. EMERGENCY ACTION AND TREATMENT

ELECTRICAL SHOCK - Immediate action is essential. Severe electric shock may affect
heart action and breathing.
Make sure it is safe to approach. If the casualty is in contact with a live conductor, isolate by
switching off the supply. See section 5 "EMERGENCY SHUTDOWN".
If this is not possible, or it is doubtful whether the system is electrically isolated, stand on dry
insulating material and pull or push the casualty clear using dry insulating material, e.g. wood,
plastic, fabrics etc.
If necessary give artificial respiration. Seek the assistance of others to summon medical
attention.
ELECTRICAL BURNS - Apply a dry sterile dressing.
ELECTROLYTE CONTACT - EYES - Irrigate the eyes with a saline solution. If saline
solution is not available wash with clean running water for at least 10 minutes
SKIN - Wash skin burns with plenty of clean water. Remove any contaminated clothing.
Cover the area with dry gauze.

IN ALL CASES SEEK IMMEDIATE MEDICAL ATTENTION.

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

1.5. BATTERY

WARNING : IN CASES WHERE THE UNIT IS NOT BEING USED, E.G.


DURING MAINTENANCE, IT IS RECOMMENDED TO
DISCONNECT THE BATTERY TO AVOID IT DISCHARGING
AND BEING DAMAGED.

Nature of hazard.
The hazards are :

Risk of electric shock


Risk of electric burns
Risk of chemical burns
Risk of poisoning

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 IF THE EARTH FAULT ALARM IS ACTIVE DO NOT CARRY


OUT MAINTENANCE ON THE BATTERY.

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


WORKING WITH BATTERIES. USE PROPERLY
INSULATED TOOLS.

CHEMICAL BURNS FROM ELECTROLYTE

The electrolyte is Potassium Hydroxide (Caustic Potash). It is corrosive to clothing and to


living tissue. Even minute traces can cause irritation and make holes in clothes.
Protect the eyes nose and mouth either with goggles and face mask or wear a full face visor.
Protect the body with all enclosing overalls.
Protect the hands with gauntlets.
Protect the feet with boots that have sealed seams. Stitched seams can allow seepage.
An eyewash must be available and any splashes must be flooded with copious amounts of
water or saline solution to dilute the electrolyte. Seek medical attention.
Neutralising agent must be on hand. Scatter it on any electrolyte spills.

Page 10 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

NOTE: Lead acid electrolyte is acidic, Nickel Cadmium electrolyte is alkaline so


different neutralising agents are needed.

POISONING

If electrolyte is swallowed it will be corrosive to internal organs.


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

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

Q = 55 x N x I ( for vented cells )

Where
Q = The required volume flow in litres / hour
N = The number of cells
I = The maximum charge current

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

1.6. COSHH STATEMENT

When this equipment finally reaches the end of its useful life it must be disposed of with due
care. It contains material which could present a variety of hazards to the environment and to
living organisms if not dealt with properly. Contact a reputable disposal service. The
following information is a guide to the disposal problems as known at the time of
manufacture.

BATTERY ELECTROLYTE

Nickel Cadmium batteries contain a corrosive electrolyte of Potassium Hydroxide (Caustic


Potash). It must never be washed into public or general-purpose drains.

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 semi-
conductors 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

Restricted Sales Distribution

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

Page 13 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

2. DESCRIPTION AND OPERATION

Title Page

2.1. DESCRIPTION 14

2.2. TOPOLOGY 14

2.3. OPERATING MODES 17

2.1. DESCRIPTION

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

2.2. TOPOLOGY

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

STATIC
SWITCH

CHARGER 2 INVERTER 2 STATIC


SWITCH

BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH

BATTERY

Figure 2.1 : Block Diagram

Page 14 of 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

Figure 2.2 : Voltage Current Characteristic of Charger

RECTIFIER/CHARGER

Converts the Primary AC supply to a regulated D.C. voltage which charges the battery,
powers the inverter and therefore the load. It operates in four possible modes.

Mode 1. FLOAT MODE. This is the normal mode. It is a constant-voltage charge mode so
battery charge current will tend to taper off to near zero as the battery becomes
fully charged. The voltage chosen is that value at which the internal losses are
compensated by the charge current into a charged battery. The battery is
maintained fully charged yet remains below gassing voltage so that the rate of
loss of electrolyte is negligible.

Mode 2. AC SUPPLY FAIL MODE. When the power to the charger is interrupted the
charger stops and without any switching taking place or operator intervention the
battery supplies the inverter and hence the load.

Mode 3. CHARGE MODE Automatically selected when the AC supply is restored.


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

Mode 4. BOOST MODE Very high constant voltage charge. Intended for use at
commissioning to complete the forming process of the battery plates. It can only
be engaged manually, by an operator. It is terminated either manually or by an
inbuilt clock. For safety the battery charging current limit threshold reduced
during BOOST mode.

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. NORMAL Constant voltage output regulated to ±1% for power loading between
0 and 105%.

Mode 2. OVERLOAD. 105% to 150%.of rated load. Constant voltage output but 10
minute timer initiated which upon expiring will shutdown the inverter. This is
long enough to cope with start up surges and current inrushes in the load.

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

Mode 3. CURRENT LIMIT. When the load is 150% or more of nominal then the inverter
changes to a constant current characteristic to protect itself. This can result in the
output voltage falling drastically. If reserve is available it will have transferred to
reserve immediately instead. If transfers are inhibited for any reason then the
inverter will continue in current limit until either the load subsides to normal or
the 10 minute timer expires.

STATIC SWITCH

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

Mode 4. INVERTER TO LOAD. This is the normal mode for the unit and is automatically
selected whenever possible.

Mode 5. RESERVE TO LOAD. Transfer to reserve occurs automatically when certain


specified abnormal conditions prevail. It returns to inverter 10 seconds after the
alarm conditions clear.

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

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

BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH

BATTERY

Figure 2.3 : Normal Mode

The two inverters power the load in parallel sharing the load between them. They are each
synchronised to the reserve supply.

Page 17 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

PRIMARY AC SUPPLY FAIL MODE

RESERVE
TRANSFORMER
RESERVE
SUPPLY

STATIC
SWITCH

CHARGER 2 INVERTER 2 STATIC


SWITCH

BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH

BATTERY

Figure 2.4 : Primary AC Supply Fail Mode

The reserve supply may or may not be available depending on the configuration of supplies
into the UPS. Each charger stops and their respective batteries each power the inverter and
hence the load. The DC voltage falls and the following alarms occur
M A IN S
FA IL

FLO A T
V O LTA GE

INVERTER
SHUTDOWN
IMMINENT

LO W DC TRIP

Figure 2.5 : DC Alarms During Primary Supply Failure


When the primary AC supply returns the charger will start in Float Mode after a short AC
supply failure or Charge Mode after a long AC supply Failure.

Page 18 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

RESERVE-TO-LOAD MODE
RESERVE
TRANSFORMER
RESERVE
SUPPLY

STATIC
SWITCH

CHARGER 2 INVERTER 2 STATIC


SWITCH

BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH

BATTERY

Figure 2.6 : Reserve to Load


mode is selected if:

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

Page 19 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

MAINTENANCE BYPASS MODE

Used by Maintenance Engineer to facilitate safe maintenance.


RESERVE
TRANSFORMER
RESERVE
SUPPLY

STATIC
SWITCH

CHARGER 2 INVERTER 2 STATIC


SWITCH

BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH

BATTERY

Figure 2.7 : Maintenance Bypass Mode

CAUTION: INDISCRIMINATE OPERATION OF THE MAINTENANCE


SWITCH MAY JEOPARDISE THE LOAD AND THE UPS.
SEE SECTION 5. OPERATING INSTRUCTIONS.

Page 20 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

ONE UPS FAIL


RESERVE
TRANSFORMER
RESERVE
SUPPLY

STATIC
SWITCH

CHARGER 2 INVERTER 2 STATIC


SWITCH

BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH

BATTERY

Figure 2.8 : One UPS Fail

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

Page 21 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

3. SYSTEM SPECIFICATION

Title Page

3.1. CHARACTERISTICS 22

3.1. CHARACTERISTICS

CHARGER

ƒ Nominal AC supply voltage: 415 V


ƒ Frequency: 50 Hz
ƒ Maximum current per phase: 150 A
ƒ Floating voltage: 413,13 V
ƒ Charge voltage : 483,45 V
ƒ Boost voltage : 498,1 V
ƒ Charger nominal current: 209 A
ƒ Maximum heat dissipation: 3360 W
ƒ High voltage setting: triggering: 529 V

ƒ Battery KBM310
ƒ Capacity: 310 Ah
ƒ Number of cells 293
ƒ Autonomy 60 min

INVERTER

ƒ Inverter nominal power: 70 kVA


ƒ Inverter nominal voltage: 110 V
ƒ Inverter nominal frequency: 50 Hz
ƒ Inverter nominal current: 636,4 A
ƒ Reserve supply nominal voltage 415 V
ƒ Maximum heat dissipation 6,2 kW
ƒ High voltage setting: triggering: 529 V

Page 22 of 68
EQUIPMENT POWER SUPPLY LOAD
CHARGER TEST WO: 15939 Item: CH1 Voltage 415 V 3 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L09-0831 Frequency 50 Hz 209 A 293 Cells
TAG CUSTOMER : Battery type : Vented Ni Cd

PRELIMINARY CHECK AUTOMATIC MONITORING AND OPTIONS


Dielectric 2000 Vac ~ / ground X Equalizing / Floating 15 H 5 min X
Dielectric 2000 Vac = / ground X Equalizing / Floating by battery current checking N/A
Dielectric 2000 Vac ~/= X Boost time 5 H X
Insulation 500 Vdc R > 10 MΩ X Compensation U= f (θ°C) ± mV / °C / cells N/A
Ground continuity 25Adc R < 0,10 Ω X Battery current limitation 62.0 A equalize / float X
Protection device calibration X Batt. test: 323.90 V Time 3 min. Setting 337.00 V X
Earth fault monitoring X
Mains fault monitoring X
SAFETY AND ALARMS Output X
Charger stop alarm X Power sharing of charger X
Input protection X Internal lightning X
DC fuse tripping X Anti-condensation heater X
Signalling test X Communication Type : Modbus X
Remote alarm test X Type : Aucun X
Test instrument calibration X
Upper limit disconnecting / Reset 529.00 V - V CHECKING
Low limit alarm / Reset - V - V Phase equilibrium (3 phases) X
NO LOAD TEST AND DC RIPPLE Regulation ± 1.0 % NOK X
Losses no load Pv = 640.0 W FAUX τ Ripple without battery ≤ 1.0 % X
DC ripple without battery : τ= 0.42931 % η Efficiency ≥ 95.0 % X

CONTROL Charge Ufloat = 413.10 V at In/2 Ucharge = 483.50 V at In/2 Uboost = 498.10 V Lim. Iboost = 62 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.0 456.0 455.0 485.1 19.3 1.38
- 10 % In 374.0 375.0 374.0 484.5 206.0 1.30
Nominal U In 416.0 148.0 417.0 147.0 416.0 147.0 104100.0 484.5 206.0 99807 95.88 0.98 2.08
Nominal U Lim. I 415.0 148.0 416.0 148.0 415.0 147.0 472.0 209.0 2.18
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X

EMC Directive : IEC 62040 - 2 LV Directive : IEC 62040 - 1 - 2


Comments : Date and customer's visa :

Tested by : MMO Date : 12/8/2009 Checked by : LDU Date : 12/08/09


Page
Charger Test Reference PGE 18 UK
Index
EQUIPMENT LOAD POWER SUPPLY
INVERTER TEST WO: 15939 Item: INV1 Voltage 110 V 1 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L09-0831 Frequency 50 Hz 209 A 293 Cells
TAG CLIENT : Power 70 kVA Battery type : Vented Ni Cd

PRELIMINARY CHECK OPTIONS


Dielectric 2000 Vac = / ground X Precharge DC N/A
Dielectric 2000 Vac ~ / ground X Emergency Power Off N/A
Dielectric 2000 Vac ~/= X AC earth fault monitoring N/A
Insulation 500 Vdc R > 10 MΩ X Output X
Ground contunuity 25Adc R < 0,10 Ω X Internal ligthning X
Protection device calibration X Anti-condensation heater X
Communication Types : Modbus Aucun X

SAFETY AND ALARMS TRANSFER AND BYPASS


Inverter stop alarm X Inverter type ON LINE X OFF LINE X
Fan failure X Transfer time Main->Inv 0 ms Inv->Main 0 ms X
Signalling test X Synchronisation limit (Volts) ∆U = 0.0 V X
Remote alarm test X Synchronisation limit (Degrees) ∆φ = 0.00 ° X
Test instrument calibration X Bypass frequency limits 3.00 % X
High DC Voltage / Threshold 572.00 V - V Bypass voltage limits 10.00% X
Imminent Shutdown / Threshold - V - V Inverter -> Mains transfer no-break X
End Of Discharge / Threshold - V - V Mains -> Inverter transfer no-break X
NO LOAD TEST Manual transfer no-break X
Losses no load Pv = 2670.0 W
Voltage no load US = 110.00 V CHECKING
Frequency no load F = 50.00 Hz Phase equilibrium (in 3 Ph) N/A
CURRENT SETTINGS AND BRIDGE TYPE Regulation ± 1.0 % X
10 min overload at cos φ=1 I = 574.6 A τ Distortion = 3% at cosφ = 1 X
Overload transfer at cosφ=1 I = 547.3 A η Efficiency ≥ 92.0 % X
Short circuit I = 1190.0 A Bridge type : IFH42S400

UDC IDC P( U x I ) U12 U23 U31 I1 I2 I3 Ptotale cos φ η τ


REGULATION
V A W V A W %
Ubatt. High 0,1 In 484.5 19.2 9302.4 109.6 61.3 6718.5 1 72.2 2.4
Ubatt. High In 481.7 162.0 78035.4 109.0 639.0 69651.0 1 89.3 2.8
Ubatt. Low 0,5 In 302.0 128.0 38656.0 109.4 319.6 34964.2 1 90.4 2.4
Ubatt. Low In 301.4 256.0 77158.4 109.0 639.0 69651.0 1 90.3 2.6
SUBJECT CHECK LIST CHECKED CUST. COMMENTS
External spect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs in file X
- Technical sheet X
- Drawings ,parts list X
- Layout X
IEC 439 - Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies ,screws ,rivets X
- Subassembly fixing, transformers, choke X
IEC 439 - Diodes and thyristors mounting on heatsink X
- Front panel removal X
IEC 73H0354 - Terminal block accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
EMC directive : IEC 62040 - 2 LV directive : IEC 62040 - 1 - 2
Comments : Date and Customer's visa :

Tested by : MMO Date: 12/8/2009 Checked by : LDU Date: 12/08/09


Page
Inverter test Reference PGE 20 UK
Index
EQUIPMENT POWER SUPPLY LOAD
CHARGER TEST WO: 16939 Item: UPS1+A1+CH Voltage 415 V 3 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L08-1262 Frequency 50 Hz 209 A 293 Cells
TAG CUSTOMER : Battery type : Vented Ni Cd

PRELIMINARY CHECK AUTOMATIC MONITORING AND OPTIONS


Dielectric 2000 Vac ~ / ground X Equalizing / Floating 15 H 5 min X
Dielectric 2000 Vac = / ground X Equalizing / Floating by battery current checking N/A
Dielectric 2000 Vac ~/= X Boost time 5 H X
Insulation 500 Vdc R > 10 MΩ X Compensation U= f (θ°C) ± mV / °C / cells N/A
Ground continuity 25Adc R < 0,10 Ω X Battery current limitation 62.0 A equalize / float X
Protection device calibration X Batt. test: 323.91 V Time 3 min. Setting 336.95 V X
Earth fault monitoring X
Mains fault monitoring X
SAFETY AND ALARMS Output X
Charger stop alarm X Power sharing of charger X
Input protection X Internal lightning X
DC fuse tripping X Anti-condensation heater X
Signalling test X Communication Type : Modbus X
Remote alarm test X Type : Aucun X
Test instrument calibration X
Upper limit disconnecting / Reset 529.00 V - V CHECKING
Low limit alarm / Reset - V - V Phase equilibrium (3 phases) X
NO LOAD TEST AND DC RIPPLE Regulation ± 1.0 % NOK X
Losses no load Pv = 700.0 W FAUX τ Ripple without battery ≤ 1.0 % X
DC ripple without battery : τ= 0.47423 % η Efficiency ≥ 95.0 % X

CONTROL Charge Ufloat = 413.13 V at In/2 Ucharge = 483.45 V at In/2 Uboost = 498.10 V Lim. Iboost = 62.0 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.5 457.0 456.0 486.0 23.6 1.60
- 10 % In 373.5 375.0 374.0 485.0 207.2 1.24
Nominal U In 414.5 147.8 415.5 146.8 415.0 147.7 103700.0 485.0 206.9 100346.5 96.77 0.98 2.30
Nominal U Lim. I 414.0 149.8 415.5 148.5 415.0 149.3 475.0 211.5 2.09
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X

EMC Directive : IEC 62040 - 2 LV Directive : IEC 62040 - 1 - 2


Comments : Date and customer's visa :

Tested by : YMA Date : 31/7/2009 Checked by : LDU Date : 12/08/09


Page
Charger Test Reference PGE 18 UK
Index
EQUIPMENT LOAD POWER SUPPLY
INVERTER TEST WO: 16939 Item: UPS1+A1+INV Voltage 110 V 1 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L08-1262 Frequency 50 Hz 209 A 293 Cells
TAG CLIENT : Power 70 kVA Battery type : Vented Ni Cd

PRELIMINARY CHECK OPTIONS


Dielectric 2000 Vac = / ground X Precharge DC N/A
Dielectric 2000 Vac ~ / ground X Emergency Power Off N/A
Dielectric 2000 Vac ~/= X AC earth fault monitoring N/A
Insulation 500 Vdc R > 10 MΩ X Output X
Ground contunuity 25Adc R < 0,10 Ω X Internal ligthning X
Protection device calibration X Anti-condensation heater X
Communication Types : Modbus Aucun X

SAFETY AND ALARMS TRANSFER AND BYPASS


Inverter stop alarm X Inverter type ON LINE X OFF LINE X
Fan failure X Transfer time Main->Inv 0 ms Inv->Main 0 ms X
Signalling test X Synchronisation limit (Volts) ∆U = 0.0 V X
Remote alarm test X Synchronisation limit (Degrees) ∆φ = 0.00 ° X
Test instrument calibration X Bypass frequency limits 3.00 % X
High DC Voltage / Threshold 572.00 V - V Bypass voltage limits 10.00% X
Imminent Shutdown / Threshold - V - V Inverter -> Mains transfer no-break X
End Of Discharge / Threshold - V - V Mains -> Inverter transfer no-break X
NO LOAD TEST Manual transfer no-break X
Losses no load Pv = 2381.4 W
Voltage no load US = 109.90 V CHECKING
Frequency no load F = 50.00 Hz Phase equilibrium (in 3 Ph) N/A
CURRENT SETTINGS AND BRIDGE TYPE Regulation ± 1.0 % X
10 min overload at cos φ=1 I = 602.0 A τ Distortion = 3% at cosφ = 1 X
Overload transfer at cosφ=1 I = 574.7 A η Efficiency ≥ 92.0 % X
Short circuit I = 1246.0 A Bridge type : IFH42S400

UDC IDC P( U x I ) U12 U23 U31 I1 I2 I3 Ptotale cos φ η τ


REGULATION
V A W V A W %
Ubatt. High 0,1 In 485.0 18.2 8827.0 109.7 61.7 6768.5 1 76.7 2.6
Ubatt. High In 482.0 152.7 73601.4 109.3 620.0 67766.0 1 92.1 2.7
Ubatt. Low 0,5 In 294.8 128.2 37793.4 109.5 318.1 34832.0 1 92.2 2.9
Ubatt. Low In 294.5 246.7 72653.2 109.3 622.0 67984.6 1 93.6 2.8
SUBJECT CHECK LIST CHECKED CUST. COMMENTS
External spect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs in file X
- Technical sheet X
- Drawings ,parts list X
- Layout X
IEC 439 - Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies ,screws ,rivets X
- Subassembly fixing, transformers, choke X
IEC 439 - Diodes and thyristors mounting on heatsink X
- Front panel removal X
IEC 73H0354 - Terminal block accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
EMC directive : IEC 62040 - 2 LV directive : IEC 62040 - 1 - 2
Comments : Date and Customer's visa :

Tested by : YMA Date: 4/8/2009 Checked by : LDU Date: 12/08/09


Page
Inverter test Reference PGE 20 UK
Index
EQUIPMENT POWER SUPPLY LOAD
CHARGER TEST WO: 15939 Item: CH2 Voltage 415 V 3 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L09-0831 Frequency 50 Hz 209 A 293 Cells
TAG CUSTOMER : Battery type : Vented Ni Cd

PRELIMINARY CHECK AUTOMATIC MONITORING AND OPTIONS


Dielectric 2000 Vac ~ / ground X Equalizing / Floating 15 H 5 min X
Dielectric 2000 Vac = / ground X Equalizing / Floating by battery current checking N/A
Dielectric 2000 Vac ~/= X Boost time 5 H X
Insulation 500 Vdc R > 10 MΩ X Compensation U= f (θ°C) ± mV / °C / cells N/A
Ground continuity 25Adc R < 0,10 Ω X Battery current limitation 62.0 A equalize / float X
Protection device calibration X Batt. test: 323.90 V Time 3 min. Setting 337.00 V X
Earth fault monitoring X
Mains fault monitoring X
SAFETY AND ALARMS Output X
Charger stop alarm X Power sharing of charger X
Input protection X Internal lightning X
DC fuse tripping X Anti-condensation heater X
Signalling test X Communication Type : Modbus X
Remote alarm test X Type : Aucun X
Test instrument calibration X
Upper limit disconnecting / Reset 529.00 V - V CHECKING
Low limit alarm / Reset - V - V Phase equilibrium (3 phases) X
NO LOAD TEST AND DC RIPPLE Regulation ± 1.0 % NOK X
Losses no load Pv = 720.0 W FAUX τ Ripple without battery ≤ 1.0 % X
DC ripple without battery : τ= 0.45417 % η Efficiency ≥ 95.0 % X

CONTROL Charge Ufloat = 413.10 V at In/2 Ucharge = 483.50 V at In/2 Uboost = 498.10 V Lim. Iboost = 62 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.0 456.0 455.0 485.1 19.4 1.40
- 10 % In 374.0 375.0 375.0 484.4 206.2 1.40
Nominal U In 415.0 149.0 416.0 147.0 415.0 149.0 104200.0 484.4 206.4 99980.16 95.95 0.98 2.20
Nominal U Lim. I 415.0 150.0 416.0 148.0 415.0 149.0 472.0 209.7 2.30
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X

EMC Directive : IEC 62040 - 2 LV Directive : IEC 62040 - 1 - 2


Comments : Date and customer's visa :

Tested by : MMO Date : 12/8/2009 Checked by : LDU Date : 12/08/09


Page
Charger Test Reference PGE 18 UK
Index
EQUIPMENT LOAD POWER SUPPLY
INVERTER TEST WO: 15939 Item: INV2 Voltage 110 V 1 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L09-0831 Frequency 50 Hz 209 A 293 Cells
TAG CLIENT : Power 70 kVA Battery type : Vented Ni Cd

PRELIMINARY CHECK OPTIONS


Dielectric 2000 Vac = / ground X Precharge DC N/A
Dielectric 2000 Vac ~ / ground X Emergency Power Off N/A
Dielectric 2000 Vac ~/= X AC earth fault monitoring N/A
Insulation 500 Vdc R > 10 MΩ X Output X
Ground contunuity 25Adc R < 0,10 Ω X Internal ligthning X
Protection device calibration X Anti-condensation heater X
Communication Types : Modbus Aucun X

SAFETY AND ALARMS TRANSFER AND BYPASS


Inverter stop alarm X Inverter type ON LINE X OFF LINE X
Fan failure X Transfer time Main->Inv 0 ms Inv->Main 0 ms X
Signalling test X Synchronisation limit (Volts) ∆U = 0.0 V X
Remote alarm test X Synchronisation limit (Degrees) ∆φ = 0.00 ° X
Test instrument calibration X Bypass frequency limits 3.00 % X
High DC Voltage / Threshold 572.00 V - V Bypass voltage limits 10.00% X
Imminent Shutdown / Threshold - V - V Inverter -> Mains transfer no-break X
End Of Discharge / Threshold - V - V Mains -> Inverter transfer no-break X
NO LOAD TEST Manual transfer no-break X
Losses no load Pv = 1680.0 W
Voltage no load US = 110.00 V CHECKING
Frequency no load F = 50.00 Hz Phase equilibrium (in 3 Ph) N/A
CURRENT SETTINGS AND BRIDGE TYPE Regulation ± 1.0 % X
10 min overload at cos φ=1 I = 602.0 A τ Distortion = 3% at cosφ = 1 X
Overload transfer at cosφ=1 I = 574.6 A η Efficiency ≥ 92.0 % X
Short circuit I = 1190.0 A Bridge type : IFH42S400

UDC IDC P( U x I ) U12 U23 U31 I1 I2 I3 Ptotale cos φ η τ


REGULATION
V A W V A W %
Ubatt. High 0,1 In 484.0 20.2 9776.8 110.0 67.6 7436.0 1 76.1 2.4
Ubatt. High In 483.0 160.0 77280.0 109.0 637.0 69433.0 1 89.8 2.5
Ubatt. Low 0,5 In 301.0 127.0 38227.0 109.5 319.3 34963.4 1 91.5 2.1
Ubatt. Low In 300.5 255.0 76627.5 110.0 637.0 70070.0 1 91.4 2.4
SUBJECT CHECK LIST CHECKED CUST. COMMENTS
External spect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs in file X
- Technical sheet X
- Drawings ,parts list X
- Layout X
IEC 439 - Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies ,screws ,rivets X
- Subassembly fixing, transformers, choke X
IEC 439 - Diodes and thyristors mounting on heatsink X
- Front panel removal X
IEC 73H0354 - Terminal block accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
EMC directive : IEC 62040 - 2 LV directive : IEC 62040 - 1 - 2
Comments : Date and Customer's visa :

Tested by : MMO Date: 12/8/2009 Checked by : LDU Date: 12/08/09


Page
Inverter test Reference PGE 20 UK
Index
EQUIPMENT POWER SUPPLY LOAD
CHARGER TEST WO: 16939 Item: UPS2+A3+CH Voltage 415 V 3 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L08-1262 Frequency 50 Hz 209 A 293 Cells
TAG CUSTOMER : Battery type : Vented Ni Cd

PRELIMINARY CHECK AUTOMATIC MONITORING AND OPTIONS


Dielectric 2000 Vac ~ / ground X Equalizing / Floating 15 H 5 min X
Dielectric 2000 Vac = / ground X Equalizing / Floating by battery current checking N/A
Dielectric 2000 Vac ~/= X Boost time 5 H X
Insulation 500 Vdc R > 10 MΩ X Compensation U= f (θ°C) ± mV / °C / cells N/A
Ground continuity 25Adc R < 0,10 Ω X Battery current limitation 62.0 A equalize / float X
Protection device calibration X Batt. test: 323.91 V Time 3 min. Setting 336.95 V X
Earth fault monitoring X
Mains fault monitoring X
SAFETY AND ALARMS Output X
Charger stop alarm X Power sharing of charger X
Input protection X Internal lightning X
DC fuse tripping X Anti-condensation heater X
Signalling test X Communication Type : Modbus X
Remote alarm test X Type : Aucun X
Test instrument calibration X
Upper limit disconnecting / Reset 529.00 V - V CHECKING
Low limit alarm / Reset - V - V Phase equilibrium (3 phases) X
NO LOAD TEST AND DC RIPPLE Regulation ± 1.0 % NOK X
Losses no load Pv = 570.0 W FAUX τ Ripple without battery ≤ 1.0 % X
DC ripple without battery : τ= 0.43299 % η Efficiency ≥ 95.0 % X

CONTROL Charge Ufloat = 413.1 V at In/2 Ucharge = 483.45 V at In/2 Uboost = 498.10 V Lim. Iboost = 62 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.0 457.0 456.0 485.0 23.6 1.63
- 10 % In 373.0 375.0 373.0 485.0 207.0 1.30
Nominal U In 414.5 146.9 416.5 146.0 415.0 145.9 103300.0 485.0 206.9 100346.5 97.14 0.98 2.10
Nominal U Lim. I 415.0 148.7 417.0 147.1 415.5 147.6 474.0 211.1 2.20
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X

EMC Directive : IEC 62040 - 2 LV Directive : IEC 62040 - 1 - 2


Comments : Date and customer's visa :

Tested by : YMA Date : 31/7/2009 Checked by : LDU Date : 12/08/09


Page
Charger Test Reference PGE 18 UK
Index
EQUIPMENT LOAD POWER SUPPLY
INVERTER TEST WO: 16939 Item: UPS2+A3+INV Voltage 110 V 1 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L08-1262 Frequency 50 Hz 209 A 293 Cells
TAG CLIENT : Power 70 kVA Battery type : Vented Ni Cd

PRELIMINARY CHECK OPTIONS


Dielectric 2000 Vac = / ground X Precharge DC N/A
Dielectric 2000 Vac ~ / ground X Emergency Power Off N/A
Dielectric 2000 Vac ~/= X AC earth fault monitoring N/A
Insulation 500 Vdc R > 10 MΩ X Output X
Ground contunuity 25Adc R < 0,10 Ω X Internal ligthning X
Protection device calibration X Anti-condensation heater X
Communication Types : Modbus Aucun X

SAFETY AND ALARMS TRANSFER AND BYPASS


Inverter stop alarm X Inverter type ON LINE X OFF LINE X
Fan failure X Transfer time Main->Inv 0 ms Inv->Main 0 ms X
Signalling test X Synchronisation limit (Volts) ∆U = 0.0 V X
Remote alarm test X Synchronisation limit (Degrees) ∆φ = 0.00 ° X
Test instrument calibration X Bypass frequency limits 3.00 % X
High DC Voltage / Threshold 572.00 V - V Bypass voltage limits 10.00% X
Imminent Shutdown / Threshold - V - V Inverter -> Mains transfer no-break X
End Of Discharge / Threshold - V - V Mains -> Inverter transfer no-break X
NO LOAD TEST Manual transfer no-break X
Losses no load Pv = 2435.0 W
Voltage no load US = 110.10 V CHECKING
Frequency no load F = 49.99 Hz Phase equilibrium (in 3 Ph) N/A
CURRENT SETTINGS AND BRIDGE TYPE Regulation ± 1.0 % X
10 min overload at cos φ=1 I = 602.0 A τ Distortion = 3% at cosφ = 1 X
Overload transfer at cosφ=1 I = 574.7 A η Efficiency ≥ 92.0 % X
Short circuit I = 1202.0 A Bridge type : IFH42S400

UDC IDC P( U x I ) U12 U23 U31 I1 I2 I3 Ptotale cos φ η τ


REGULATION
V A W V A W %
Ubatt. High 0,1 In 485.0 19.9 9651.5 110.0 61.6 6776.0 1 70.2 3.0
Ubatt. High In 482.0 153.2 73842.4 109.2 619.3 67627.6 1 91.6 3.0
Ubatt. Low 0,5 In 295.6 127.5 37689.0 109.6 317.9 34841.8 1 92.4 3.0
Ubatt. Low In 294.9 247.8 73076.2 109.2 622.0 67922.4 1 92.9 2.8
SUBJECT CHECK LIST CHECKED CUST. COMMENTS
External spect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs in file X
- Technical sheet X
- Drawings ,parts list X
- Layout X
IEC 439 - Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies ,screws ,rivets X
- Subassembly fixing, transformers, choke X
IEC 439 - Diodes and thyristors mounting on heatsink X
- Front panel removal X
IEC 73H0354 - Terminal block accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
EMC directive : IEC 62040 - 2 LV directive : IEC 62040 - 1 - 2
Comments : Date and Customer's visa :

Tested by : YMA Date: 4/8/2009 Checked by : LDU Date: 12/08/09


Page
Inverter test Reference PGE 20 UK
Index
CHLORIDE
INDUSTRIAL SYSTEMS

4. INSTALLATION
Title Page

4.1. HANDLING ON ARRIVAL 23

4.2. STORAGE 24

4.3. PUTTING INTO INSTALLED POSITION 24

4.4. ELECTROLYTE / CELL OIL 25

4.4.1. Cells delivered filled 25

4.4.2. Cells delivered empty 25

4.5. CABLE ENTRIES 25

4.6. TERMINAL CONNECTIONS 25

4.6.1. Phase rotation 25

4.6.2. Battery 25

4.6.3. Neutral 26

4.6.4. Earth 26

4.7. VENTILATION 26

4.8. BATTERY-VENTED CADMIUM NICKEL 26

4.9. BATTERY INSTALLATION 26

4.1. HANDLING ON ARRIVAL

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

NOTE: The battery and equipment cubicle often arrive separately.

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

4.3. PUTTING INTO INSTALLED POSITION

The equipment will have to be lifted from its pallet and manoeuvred into position. Note that
battery cubicles are extremely heavy and adequately strong lifting gear is needed.
Once in position adjacent cubicles should be fastened to each other by means of through bolts
(these are provided inside plastic bags inside the cubicles), and to the floor using anchor
bolts. Before fitting each anchor bolt, level the cubicles for both horizontal and vertical planes
as required using incompressible shims.

The procedure for fixing the panels together is as follows:


Take the kit comprising of 4 screws and nuts (HM6 x 70mm)
Remove the 2 transfer screws on the separating panel
But the cubicles together holding the separating panel in place. The separating panel is
sandwiched between the cubicles
Take the 4 screws and open the panel doors
Put the screws through the holes in the uprights which go through the separating panel.
There are 2 at the top and 2 at the bottom. Put the nut on the screw and tighten.

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4.4. ELECTROLYTE / CELL OIL

4.4.1. Cells delivered filled


Check the level of electrolyte. The cells must have a level of electrolyte above the plates. If it
is not the case, adjust the level of electrolyte with distilled or deionised water to 5 mm above
the plate tops. Cells delivered filled have already the cell oil in place.

4.4.2. Cells delivered empty


Fill empty cells with electrolyte to 5 mm above the plate tops. Then add the oil with the
syringe, according to the quantity indicated in the table on the reverse of this card.
NOTE: Please, always refer to manufacturer’s manual.

4.5. CABLE ENTRIES

Refer to the general arrangement drawing for cable entry positions.


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

4.6. TERMINAL CONNECTIONS

4.6.1. Phase rotation

The equipment requires the phase rotation to be correct for correct operation. Terminals are
labelled for that purpose.

4.6.2. Battery

The battery cable should be connected with the battery fuse removed and the battery isolator
OFF. Check and double check that the polarity of the battery connection is correct. An error
here can cause major damage to the system.

WARNING : DO NOT CLOSE BATTERY ISOLATOR OR FIT FUSES


UNTIL THE FILTER CAPACITORS HAVE BEEN PRE-
CHARGED BY THE CHARGER.

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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 40°C temperature range, although, ideally the ambient temperature
should be below 25°C.
The heat can be removed from the equipment room by a forced cooling ventilation system or,
alternatively, an air conditioning system.
The required air changes per hour will depend on the system rating, the heat loss and the
cooling air temperature.

4.8. 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: REMOVE RINGS AND METAL WATCHSTRAPS WHEN


WORKING ON BATTERIES. ALSO USE INSULATED TOOLS.

It is the responsibility of the installer to arrange suitable protection.


The installer will have to connect the inter-cell cables as shown in the battery diagram in
section 10 of this manual.
Before starting, remove the battery fuses and ensure the battery breaker or isolator is OFF.

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BATTERY INSTALLATION CHECK LIST

Battery isolator OFF


Battery fuse removed
Batteries on each group interconnected.
Voltage check of each battery group
Check no short from battery to earth
Check metal battery cubicles (or metal stands) are earthed.
Interconnect the battery in accordance with Battery Diagram.
Use voltmeter to check the voltage of each half of the battery.
Terminate the cables linking the battery and the UPS.
Make absolutely sure these are the correct polarity, as an error will cause substantial damage
when the equipment is started up.

CAUTION: DO NOT CONNECT BATTERY POWER TO THE UPS UNTIL


THE RECTIFIER SOFT START HAS BEEN ALLOWED TO
PRECHARGE THE SMOOTHING CAPACITORS SEE
SECTION 5 FIRST START UP.

Check the ambient temperature and once the system is running measure the temperature in the
battery cubicle.

Once the system is running check the charge voltage in:


− FLOAT MODE
− CHARGE MODE
− BOOST MODE

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5. OPERATING INSTRUCTIONS

Title Page

5. OPERATING INSTRUCTIONS 28

5.1. LIGHT EMITTING DIODES (LEDS) 29

5.2. DISPLAY 30

5.3. CONTROL PUSH-BUTTONS 31

5.4. PRESENTATION OF THE MENUS 32

5.5. GENERAL MENU 32

5.6. UPS BLOCK MENUS 33

5.7. CONTROL PANEL MENUS 36

5.8. CHANGE CHARGER MODE 41

5.9. MEASURES, FAULTS AND WARNINGS 42

5.10. HEADING 42

5.11. RECTIFIER/CHARGER INFORMATION 45

5.12. BATTERY INFORMATION 46

5.13. INVERTER INFORMATION 46

5.14. RESERVE INFORMATION 47

5.15. LOAD AND STATIC SWITCH INFORMATION 47

5.16. OPERATING INSTRUCTIONS 48


5.16.1. First start-up 48
5.16.2. Maintenance procedure 50
5.16.3. Transfer to maintenance for a stand-alone inverter 52
5.16.4. Return from maintenance for a stand-alone inverter 52
5.16.5. Global maintenance procedure 53
5.16.6. Black start procedure 53

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The UPS incorporates the necessary controls, instruments and indicators to allow the operator to
monitor the system status and performance and take any appropriate action. Furthermore, interfaces
are available, which allow extended monitoring and control, as well as service functions.

5.1. LIGHT EMITTING DIODES (LEDS)

The UPS has three Light Emitting Diodes (LEDs) to indicate the overall system operation status as
well as the condition of the sub-assemblies. These LEDs interact with the active mimic diagram
displayed on the graphical display.

Led view Led colour Description Comments

Green UPS normal operation AC load supplied by the inverter


and the charger is running

Green flashing load on reserve, or Load powered by reserve or


inverter running on inverter running on battery
battery

Orange UPS warning One or more subassemblies are


affected but UPS not stopped

Red UPS fault One or more subassemblies are


faulty and stopped or manually
stopped.
STO

Red flashing CAN communication The UPS communication CAN BUS


fault is not correctly plugged or in
failure.

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.

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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.

1 3 2

5 4
The display has two operating modes:

1. Visualization of an active mimic diagram which gives a graphic representation of the UPS
status.

2. Navigation through various menus for visualization of status or measurements information or


possible actions on the UPS.

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User push-buttons used to control the Graphical Liquid Crystal Display:

Select previous
Up in menus.

Select next
Down in menus.

Validate parameters
OK Enter in menus.

Cancel parameters
C Back in menus.

User push-button used to control the alarm buzzer:

Cancel audible alarm


It cancels internal audible alarm until a new alarm occurs.

5.3. CONTROL PUSH-BUTTONS

In the right part of the display there are two further push-buttons to control the UPS:

Starts / Stops rectifier/charger operation:


The control incorporates a safety feature to prevent inadvertent operation yet still
allow rapid shutdown in the event of an emergency. This shall be achieved by
pressing the button for 2 seconds before the charger stops. “SWITCH OFF
0 1
CHARGER” message is temporarily displayed on the LCD and an OFF pictogram
Rectifier
appears on the charger block.
To start the charger, it is necessary to push this same button for 1 second: “SWITCH
ON CHARGER” message is temporarily displayed and the OFF pictogram on the
charger block disappears.

Starts / Stops inverter operation :


The control incorporates a safety feature to prevent inadvertent operation yet still
allow rapid shutdown in the event of an emergency. This shall be achieved by
pressing the “STOP” button for 2 seconds before the inverter stops. “SWITCH OFF
0 1 INVERTER” message is temporarily displayed on the LCD and an OFF pictogram
Inverter appears on the inverter block.
To start the inverter, it is necessary to push this same button for 1 second. “SWITCH
ON INVERTER” message is temporarily displayed on the LCD and the OFF
pictogram on the inverter block disappears.

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

5.4. PRESENTATION OF THE MENUS

The information available on the display is of two types: mimic diagram or menu.
The UPS is structured in "blocks". The organization of the information in the menus is the reflection
of this structure.
You will find in the General Menu all the UPS blocks as well as some controls.

Examples of menus:

MENU 
 
 Charger 
 Battery  CHARGER 
 
 Inverter   Status 
 Reserve   Changing Mode  CHARGER MEASURES 
 AC Load   
 Measurements   UDC  =  220.1 V 
   Faults   IDC  =   60.0 Amp 
 Warnings   U12  =  241.2 V 
   U23  =  242.0 V 
General menu
 U31  =  241.0 V 
 I1   =   70.0 Amp 
Charger menu

Charger measures
(three-phase UPS)
5.5. GENERAL MENU

The general menu allows access to the following sub-menus:

Sub-menus for the five UPS blocks:


ƒ Charger
ƒ Battery
ƒ Inverter
ƒ Reserve
ƒ AC Load
Sub-menus for the controls:
ƒ Reset
ƒ Black Start (Optional)
ƒ Event log
ƒ Display Setting
ƒ Contact
ƒ About

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To navigate in the menus, use the push-buttons:

to come back to the previous item

to move to the next item

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

NOTES:
ƒ The menus and sub-menus are circular roll down menus.
ƒ The selected item is indicated by an arrow (4) at the beginning of the line.

5.6. UPS BLOCK MENUS

1. CHARGER

MENU 
 
 Charger 
 Battery 
 Inverter 
 Reserve 
 AC Load 
 

This module allows entry to the following menus:

CHARGER 
  ƒ Charger status menu (to display the charger operational
 Status 
status).
 Changing Mode 
 Measurements  ƒ Change charger mode menu (used to change the battery
 Faults  charge mode).
 Warnings 
  See Change charger mode chapter for more details.
ƒ Charger measurements menu (for a list of measurements
on the charger).
See Measures and Faults chapter for more details.
ƒ Charger faults menu (for a list of active faults on the
charger).
ƒ Charger warnings menu (for a list of active warnings on
the charger).

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2. BATTERY

MENU 
 
 Charger 
 Battery 
 Inverter 
 Reserve 
 AC Load 
 

This module allows entry to the following menus:

BATTERY 
  ƒ Battery status menu (to display the battery operational
 Status  status).
 Measurements 
 Faults  ƒ Battery measurements menu (for a list of measurements
 Warnings  on the battery).
  
  ƒ Battery faults menu (for a list of active faults on the
battery).
ƒ Battery warnings menu (for a list of active warnings on
the battery).

3. INVERTER

MENU 
 
 Charger 
 Battery 
 Inverter 
 Reserve 
 AC Load 
 

This module allows entry to the following menus:

INVERTER 
  ƒ Inverter status menu (to display the inverter operational
 Status  status).
 Measurements 
 Faults  ƒ Inverter measurements menu (for a list of measurements
 Warnings  on the inverter).
 
  ƒ Inverter faults menu (for a list of active faults on the
inverter).
ƒ Inverter warnings menu (for a list of active warnings on
the inverter).

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4. RESERVE SUPPLY

MENU 
 
 Charger 
 Battery 
 Inverter 
 Reserve 
 AC Load 
 

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

RESERVE 
  ƒ Reserve supply status menu (to display the reserve supply
 Status 
operational status)
 Measurements 
 Faults  ƒ Reserve supply measurements menu (for a list of
 Warnings  measurements on the reserve supply)
 
  ƒ Reserve supply faults menu (for a list of active faults on the
reserve supply)
ƒ Reserve supply warnings menu (for a list of active
warnings on the reserve supply)

5. AC LOAD

MENU 
 
 Charger 
 Battery 
 Inverter 
 Reserve 
 AC Load 
 

This module allows entry to the following menus:

AC LOAD 
  ƒ AC load status menu (to display the AC load operational
 Status  status)
 Measurements 
 Faults  ƒ AC load measurements menu (displays the list of
 Warnings  measurements on the AC load)
 
  ƒ AC load faults menu (for a list of active faults on the AC
load)
ƒ AC load warnings menu (for a list of active warnings on
the AC load)

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5.7. CONTROL PANEL MENUS

1. RESET

MENU 
 
  Inverter 
  Reserve 
  AC Load 
  Reset 
  Black Start 
 

This module allows entry to the following menus:

RESET 
  ƒ RESET charger menu (to erase the memorized charger
  Charger Reset  defaults)
  Inverter Reset 
  Event Log Reset  ƒ RESET inverter menu (to erase the memorized inverter
  Autonom Calcul Rst  and static switch defaults)
 
  ƒ RESET Log event menu
ƒ RESET Autonom Calcul Rst menu (to get the initial
value of Battery Capacity used for the calculation of the
battery autonomy

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


OK of the RESET to erase. The display will automatically
go back to the general menu.
To erase the charger and inverter blocks stored defaults,
repeat the previous operation for both parts.

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2. BLACK START (OPTIONAL)

MENU 
 
  Inverter 
  Reserve 
  AC Load 
  Reset 
  Black Start 
 

This module is only available on parallel inverters. It allows entry to the following menu:

BLACK START 
  This menu gives the possibility to start parallel inverters, if the
 Start the Inverter  Reserve Supply is not present:
 without Reserve? 
    ƒ Start both inverters by the control push buttons on each
  NO  display: the inverters will not yet start, as the Reserve
  YES  Supply is not present.
 
  ƒ Select the Black Start menu on one of both inverters.
ƒ Select “YES” with the Down push-button and click on
O K to validate.
ƒ Both inverters will start simultaneously.

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3. EVENT LOG

MENU 
 
  Reserve 
  AC Load 
  Reset 
  Black Start 
  Event Log 
 

This module allows to display one by one all the events memorised into the historical record, in a
chronological order.

Example of event:
EVENT N° 1 
 Inverter Fault 
 υHigh DC voltage 
   Memorised 
  
Initiated: 
 17 fev 05 06:18:37 
 

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

Every event is detailed as follows:


ƒ The concerned block,
ƒ The text of the detected fault or alarm,
ƒ The nature of the event (indicates if the event appeared or disappeared)
ƒ The date and time when the event occurred.

The scheduling and the memorizing of the events depend on the choice of the event mode memorizing
in the Event Log:
Saturable Mode:
The first memorised event corresponds to the first fault or alarms that occurred on the
equipment, after a UPS power on, or after a Even Log reset.
The Event Log is limited up to 100 events and any more events past this limit are memorized.
The classification of the events never changes.
N°1 : the first event which has occurred (oldest).
N°100: the 100th event.

FIFO Mode:
The first event corresponds to the fault or warning memorized occurred most recently.
Once the limit of 100 events memorized in the Event log, if a new event occurs, the oldest
event of the Event log will be removed and event which has just occurred will be memorized.
The classification of the events always corresponds to the order of which has occurred of the
events.
N°1 : the most recent
N°100: oldest. (if 100 recorded events).

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

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4. DISPLAY SETTING

MENU 
 
  AC Load 
  Reset 
  Black Start 
  Event Log 
  Display Setting 

This module allows entry to the following menus:

DISPLAY SETTING 
  ƒ Serial link menu (to direct the serial link of the display
  Serial link  board)
  Language 
  Event Log Mode  ƒ Language menu (to read information in different
  language.
 
  ƒ Event Log Mode menu (to chose between the to mode of
Event Log memorizing.
Select with Up and Down push-buttons the option requested: to
validate, click on OK . You will then enter the item chosen.

SERIAL LINK: This module allows entry to the following menus indicating the two possibilities.

SERIAL LINK 
  ƒ Internal menu (to direct the serial link to SUB D9 (SK8)
  Internal  of the display board)
  External 
 Selected Link:  ƒ External menu (to direct the serial link to RJ 45 (SK6) of
 Internal  the display board)
 
Select with Up and Down push-buttons the serial link

requested: to validate, click on OK . You will then


enter the new serial link chosen.

LANGUAGE: This module allows entry to the following menus:

LANGUAGE 
  ƒ English menu (to read information in English).
  English 
  French  ƒ French menu (to read information in French).
  Spanish 
  German  ƒ Spanish menu (to read information in Spanish).
  Italian 
   
ƒ German menu (to read information in German).
  ƒ Italian menu (to read information in Italian).

To validate the language, click on O K corresponding to


your choice using arrows to go up and down. The display will
then return to the general menu.

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

EVENT LOG MODE 
  ƒ Saturable Mode (allow to memorize the first 100 events)
  Saturable Mode 
  FIFO Mode  ƒ FIFO Mode (allow to memorize permanently until the last
 Actual Setting:  100 events )
 FIFO Mode 
  Select with Up and Down push-buttons the mode requested: to
validate, click on OK . You will then enter the new mode
chosen.

It is advised to make a Reset of Event Log after having


changed mode.

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.

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5.8. CHANGE CHARGER MODE

CHARGER 
 
 Status 
 Changing Mode 
 Measurements 
 Faults 
 Warnings 
 

CHANGING MODE  In the Charger menu, click O K on Changing Mode to enter


  the sub-menu:
 Request Action 
  No Request  ƒ Request action
 Charger Status 
  Floating  ƒ Charger status
  
 

CHANGING MODE  Click O K on Request Action to enter sub-menu:


Request Actionτ  Request Action
 No Request  ƒ No request
 Floating 
 Equalisation  ƒ Floating
 Boost  ƒ Equalisation
 Battery Test  ƒ Boost
  ƒ Battery test
Select the needed mode and click O K . The display will go
back to the previous menu to display the required action and
also if the charger has really changed the mode.

Click C to come back to previous menus.


Nota: access to certain modes is not always possible depending
on battery types.

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5.9. MEASURES, FAULTS AND WARNINGS

Each sub-menu Measures, Faults and Warnings are circular roll down menus which can be scanned
with arrows :

To select previous item


To select next item

For Faults and Warnings menus, if no fault or warning is present, you can read a label saying “No
fault” or “No warning”.

5.10. HEADING

The heading displays the active mimic diagram of the UPS system (see figures below). By pressing
the
or or buttons, the user can enter the general menu. While
navigating in the menus, the user can return to the active mimic diagram by pressing the
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.

Active mimic panel Active mimic panel


(single phase output UPS) (Three-phase output UPS)

The active mimic diagram displays the following information:


9 Graphical view of the connected load,
9 Graphical view and percentage of the battery charge level,
9 Graphical view of the power flow,
9 Graphical view of the status of each subassembly.

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Below are two examples of active mimic situations:

Mains input failure


Charger stopped
AC load still supplied
Battery discharging

Active mimic panel (single phase)

UPS running
AC load supplied
Inverter not synchronised on reserve

Active mimic panel (single phase)

The display shows the following information:

1 Charger status 7 Bypass switch status


2 Battery status 8 Synchronization status
3 Inverter status 9 Battery current status
4 Static switch status 10 Output current status
5 AC load status 11 Battery charge level status
6 Reserve input status
6 8 7

1 5

9
10

11 2 3 4

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Pictograms list:

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

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

Inverter block
Inverter ON and OK
Inverter ON but with warnings ON
Inverter stopped following faults detection
Inverter voluntary OFF

Inverter waiting for start (only in parallel inverter case)

Inverter waiting for stop (only in parallel inverter case)


Communication problem with the inverter

Static switch block


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

.... cut off flow


__ continuous flow

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NOTE 1:

Pictogram voluntary OFF has priority on and .


Pictogram has priority on .

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 Warnings indications


Charger OFF Test mode
Initialisation Fan failure
Charger Stop Overload inhibit
Equalisation mode Charger in current limit
Equalisation imposed
Floating mode
Battery test mode
Battery test imposed
Boost mode

Measurements indications
Faults indications Charger output DC voltage
No fault Charger output DC current
High DC voltage Charger input voltage (between each phase)
High DC voltage memorised Charger input current (on each phase)
Too high I battery memorised Charger input frequency
Charger fuse blown Number of mains failures
Input protection open
Charger off
Wrong phase sequence
AC supply fault

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5.12. BATTERY INFORMATION

Status indications Warnings indications


Normal DC earth fault
Discharging Battery begin discharge
Charging Imminent shutdown
Fault or warning

Faults indications
No fault
Battery test fault memorised
End of discharge
Battery protection open Measurements indications
Battery voltage
Battery current
Battery temperature
Battery autonomy (%)

5.13. INVERTER INFORMATION

Status indications
Inverter synchronised
Inverter on crystal
Inverter not running
Inverter switched off

Warnings indications
No warning
Commissioning mode
Faults indications Software time-out
No fault Fan failure
Inverter switched off Inverter overload warning
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 Measurements indications
High AC voltage memorised Inverter input DC voltage
Frequency fault memorised Inverter output voltage (between phases and
neutral)
Inverter frequency

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5.14. RESERVE INFORMATION

Status indications Warnings indications


No warning ; no fault No warning
Warning ; no fault Reserve voltage fault
No warning ; fault Reserve frequency fault
Warning + fault Wrong phase sequence

Measurements indications
Reserve voltage (between phases and neutral)
Reserve frequency

5.15. LOAD AND STATIC SWITCH INFORMATION

Status indications
Load on inverter
Load on reserve
Manual bypass on
Load not supplied

Faults indications Warnings indications


No fault No warning
Static switch overload fault memorised Manual bypass closed
Inverter static switch fault memorised Static switch overload
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 (%)

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5.16. OPERATING INSTRUCTIONS

5.16.1. First start-up

Starting situation: All switches, breakers and isolators are open, except Q21 which is closed.

ƒ Check the voltage and frequency of the Reserve.


ƒ Switch on Reserve input isolator Q31.
ƒ On both UPSs, switch charger primary supply ON. Close charger AC input isolators Q3.
Wait 30 seconds for initialisation of the chargers.
ƒ 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.
ƒ Using a hand-held voltmeter, check amplitude and polarity of the charger output voltage,
on both chargers.
ƒ Also check amplitude and polarity of the battery voltage, on both batteries.
ƒ If all previous voltages are correct in amplitude and polarity, close both battery isolators
Q5.
ƒ Wait until both displays are correctly powered (no more question mark).
ƒ Operate an inverter reset on each inverter by the control push buttons (“Reset” part of the
LCD General Menu).
ƒ Close Q26 and Q27.
ƒ 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).
ƒ Using a hand-held voltmeter, check that Output Distribution is correctly powered.
ƒ On each display, check the correct display of the DC voltage (Inverter Measurement
Menu) and of the AC output voltage (AC Load Measurement Menu).
ƒ If you want to check the load transfers, proceed as follows:
¾ Turn both inverters on by the control push buttons (Push Inverter ON/OFF button
“0/1 Inverter” for 1 second, until “SWITCH ON INVERTER” is displayed on the
display): The inverters will not yet start.
¾ Press S22: INVERTER 1 will start and the Static Switch will transfer from Reserve to
INVERTER 1.
¾ Release S22: The Static Switch will transfer back from INVERTER 1 to Reserve, and
INVERTER 1 will stop.
¾ Press S23: INVERTER 2 will start and the Static Switch will transfer from Reserve to
INVERTER 2.
¾ Release S23: The Static Switch will transfer back from INVERTER 2 to Reserve, and
INVERTER 2 will stop.

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¾ 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).
ƒ Close Q23.
ƒ Open Q21.
ƒ Start both inverters by the control push buttons: both inverters will start simultaneously
once you start the second inverter.
ƒ The inverters are now running in ‘AUTOMATIC’ mode.

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5.16.2. Maintenance procedure

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

In this procedure, the inverter to be disconnected for Maintenance will be called


INVERTER M, and the Remaining inverter will be called INVERTER R.

ƒ Open Q26/Q27 of INVERTER M: the load is now supplied by INVERTER R alone.


ƒ 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).
ƒ On the right of INVERTER M, disconnect both SUB-D25 cables, “MC” and “FC” (cables
coming from INVERTER R), from the SUB-D25 socket. Plug “MC” into “FC”. (This will
cause an Inverter Fault and a Reserve Warning to occur on the display!)
ƒ Reset the inverter alarms on INVERTER R: Inverter block and Reserve are getting normal
again on the display.
ƒ In the Bypass cubicle, open the isolating terminals X943-A or X943-B connected to
INVERTER M.
ƒ Stop INVERTER M by the control push buttons.
ƒ 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.
ƒ INVERTER M is now disconnected.
ƒ 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.

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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.
ƒ Energise the DC supply to INVERTER M. Wait until the display is correctly powered (no
more question mark).
ƒ Operate an inverter reset by the control push buttons of INVERTER M.
ƒ In the Bypass cubicle, close the isolating terminals X943-A or X943-B connected to
INVERTER M.
ƒ On the right of INVERTER M, disconnect SUB-D25 cable “FC” from “MC” (cables
coming from INVERTER R) and plug these cables into the SUB-D25 socket (“MC” into
“FS” and “FC” into “MS”). This will cause an Inverter Fault and a Reserve Warning to
occur on the display, and the Reserve Static Switch of INVERTER M to be opened
(visible on the synoptic diagram of the Display).
ƒ Operate an inverter reset by the control push buttons on both inverters, in order to clear all
Warnings and Faults.
ƒ 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).
ƒ Close Q26/Q27 of INVERTER M.
ƒ Start INVERTER M: the load will be shared between both inverters.
ƒ INVERTER M is now reconnected.

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5.16.3. Transfer to maintenance for a stand-alone inverter

ƒ 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.
ƒ Stop the inverter: the load will be transferred without a break to Reserve.
ƒ Close Q21.
ƒ Open Q23 and Q22.
ƒ Isolate the inverter from DC side: Stop the charger, open Q3 and open Q5.
ƒ 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.
ƒ Before any maintenance operation, always make sure that no more voltage is present
on any part you will have to touch.

5.16.4. Return from maintenance for a stand-alone inverter

ƒ Energise the DC supply. Wait until the display is correctly powered (no more question
mark).
ƒ Operate an inverter reset by the control push buttons.
ƒ 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).
ƒ If you want to check the load transfers, proceed as follows:
¾ Turn the inverter on by the control push buttons (‘SWITCH ON INVERTER’ message
on the display): The inverter will not start.
¾ Press S22 (for INVERTER 1) or S23 (for INVERTER 2): The inverter will start and
the Static Switch will transfer from Reserve to Inverter.
¾ Release S22/S23: The Static Switch will transfer back from Inverter to Reserve, and
the inverter will stop.
¾ At the end of this test, even if the inverter is not running, turn the inverter off by the
control push buttons (‘SWITCH OFF INVERTER’ message on the display).
ƒ Close Q23.
ƒ Open Q21.
ƒ Start the inverter by the control push buttons.
ƒ The inverter is now running in ‘AUTOMATIC’ mode.

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5.16.5. Global maintenance procedure

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

5.16.6. Black start procedure

If you want to start the (parallel) inverters while the Reserve voltage is not present, you have
to use the Black Start option, on the front door display:
ƒ Power up the DC supply of the inverters, as described here before.
ƒ Wait until both displays are correctly powered (no more question mark).
ƒ Operate an inverter reset on each inverter by the control push buttons (“Reset” part of the
LCD General Menu).
ƒ Start both inverters by the control push buttons on each display: the inverters will not yet
start, as the Reserve Supply is not present.
ƒ 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.
ƒ Both inverters are now running in ‘AUTOMATIC’ mode. There is no memorisation of the
Black Start, so you don’t have to reset anything, once the Reserve Supply has come back.

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6. ROUTINE MAINTENANCE

Title Page

6.1. GENERAL 54

6.2. ONCE A WEEK 54

6.3. ONCE A MONTH 54

6.4. AT LEAST 4 TIMES PER YEAR 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.

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6.4. AT LEAST 4 TIMES PER YEAR

Check ventilation grilles


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

6.5. ANNUALLY

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

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

6.6. FANS

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

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7. FAULT DIAGNOSIS

Title Page

7. FAULT DIAGNOSIS 56

7.1. CHARGER DISPLAY MENU 57

7.2. CHARGER DEFAULTS 58

7.3. CHARGER VOLUNTARY STOPPED 59

7.4. CHARGER WARNING 59

7.5. BATTERY FAULT 60

7.6. BATTERY WARNING 60

7.7. INVERTER DISPLAY MENU 61

7.8. INVERTER FAULTS 62

7.9. INVERTER VOLUNTARY STOPPED 63

7.10. INVERTER WARNING 63

7.11. RESERVE WARNING 64

7.12. AC LOAD/ STATIC SWITCH FAULT 64

7.13. AC LOAD/STATIC SWITCH WARNING 65

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7.1. CHARGER DISPLAY MENU

Charger fault is designed by on the charger


pictogram.

Select Charger in the general menu and click on


OK to valid.

In order to have access to the Faults menu, select


Faults in the Charger menu and click on OK to
valid.

In this menu all faults appear (instantaneous and


memorized faults)

If no faults are shown on the display then No


faults appears in this menu.

Click twice on Cancel to come back to the


general menu.

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7.2. CHARGER DEFAULTS

CHARGER FAULTS POSSIBLE CAUSES SOLUTIONS

AC Supply fault Loss of AC supply, lack of one Check fault nature on the LCD
phase, too high or too low display (amplitude or phase
amplitude, wrong phase problem).
sequence for three phase charger Check input supplies.
If AC supply is OK on power
input terminals, check auxiliary
fuses on internal electronic door
(F10)
Wrong phase sequence On three phase charger, the Interchange two phases, to
phase sequence is not correct reverse direction of phase
rotation
AC voltage NOK Amplitudes of one or several Check input supply on power
phases are not OK input terminals. If AC supply is
OK on power input terminals,
check auxiliary fuses on internal
electronic door (F10)
High DC Voltage Loss of charger voltage Check all the wires connected
regulation in case of charger to the INCA circuit board. If the
alone configuration (The fault is wiring is correct, the problem
not memorized and the charger can be linked with card
runs intermittently in order to problem:
continue to supply the DC load). Call engineer.
High DC Voltage Loss of charger voltage Check all the wires connected
Memorized regulation in case of parallel to the INCA circuit board. If the
configuration charger (The fault wiring is correct, the problem
is memorized and the charger is can be linked with card
cut) . The DC load is supplied problem: Call engineer.
by the redundant charger(s) Reset this memorized fault with
the LCD display charger reset.
Too high I battery Loss of battery current Check all the wires connected
Memorised regulation. to the INCA board and the
battery current Hall effect
sensor. If the wiring is correct,
the problem can be linked with
card or sensor problem: Call
engineer.
Reset this memorized fault with
the LCD display charger reset.
Charger fuse blown Charger bridge high speed fuse Check loading, thyristors,
blown due to sudden short renew fuse, rearm the
circuit on the DC side or microswitch detector. In case of
problem on charger control a new occurrence, check the
loop. control wiring on the INCA
board. The problem can be
linked with a board: Call
engineer.

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Input protection opened Input protection tripped or Check loading and possible
opened. short circuit or overload on the
DC side. Rearm the protection.
Remote emergency stop Optional remote charger switch Check if the charger is not
is acting. (Optional switch) cut by an external remote
(or redundant high DC voltage switch.
monitor is acting).
(Check if the redundant
voltmetric relay is not acting on
the INCA board by looking at
red LED10)

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

7.3. CHARGER VOLUNTARY STOPPED

Charger switch Off The charger is cut from the Give an ON charger order with
CANDIS board. CANDIS push button.

7.4. CHARGER WARNING

CHARGER POSSIBLE CAUSES SOLUTIONS


WARNING

Fan failure One charger bridge fan is not Remove the charger AC and DC
supplied or blocked (in case of power supply, and isolate it.
forced air cooling charger Replace the fan in failure.
bridge)
DC voltage low The charger DC voltage is not Check if the DC load is not too
yet in voltage level regulation: high or if the charger is in
Overload on the DC side, or battery current limitation, by
battery is charging in current looking at IDC or Ibatt current
limitation after a discharge, or level on the display board. If
possible problem of voltage both preceeding points are not
regulation due to a too low AC satisfied, check if the AC mains
mains level. amplitude is not too low before
to call engineer.
Test mode The charger is in special Call engineer
production or commissioning
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)

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7.5. BATTERY FAULT

BATTERY FAULTS POSSIBLE CAUSES SOLUTIONS

Battery Test Fault Following an automatic or a manual Check battery connections.


Memorized battery test, a battery fault has been Check battery not damaged.
detected due a too rapid discharge Call engineer.
rate. Reset this memorized fault with
the LCD display charger reset.
End of discharge Low DC trip level has been passed. If AC supply fail, no action.
Check no charger fault.
Call engineer.
Battery protection opened Battery fuse or circuit breaker open. Check DC loading then re-
connect.

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 POSSIBLE CAUSES SOLUTIONS


WARNINGS

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

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

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7.7. INVERTER DISPLAY MENU

Inverter fault is designed by on the


inverter pictogram.

Select Inverter in the general menu and click on


OK to valid.

In order to have access to the Faults menu, select


Faults in the Inverter menu and click on OK to
valid.

In this menu all faults appear (instantaneous and


memorized faults)

If no faults are shown on the display then No


faults appears in this menu.

Click twice on Cancel to come back to the


general menu.

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7.8. INVERTER FAULTS

INVERTER FAULTS POSSIBLE CAUSES SOLUTIONS

VCE Fault M. Inverter bridge transistor Check the AC load.


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

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Frequency Fault M. Inverter output regulation problem. Check the wiring of the
inverter LION interface
board. After correction,
reset this memorized fault
with the LCD display
inverter reset.
If new occurrence, call
engineer.
Paral. Com. Flt M. Problem detected in the Check correct insertion and
communication between the wiring of optional POB
different parallel running units (in board.
case of inverter parallel running)
Microcontroller fault Inverter running stopped by a Reset this memorized fault
microcontroller fault on the Inverter with the LCD display
CUdSMC board. inverter reset.
If new occurrence, call
engineer

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

7.9. INVERTER VOLUNTARY STOPPED

Inv. switched Off The inverter is cut from the Give an ON inverter order with
CANDIS board. CANDIS push button.

7.10. INVERTER WARNING


INVERTER POSSIBLE CAUSES SOLUTIONS
WARNINGS

Redundant fan failure One inverter bridge fan is not supplied Follow the maintenance inverter
or blocked (in case of forced air cooling procedure in order to isolate the
inverter bridge) inverter part from an electrical
point of view .Replace the fan in
failure.
Inv. Overload warning 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.
S/W Time-out. Transient microcontroller problem, Call engineer
inverter may still be running.
Commissioning Running mode used for commissioning. Modify the configuration with
Operator has forgotten to replace the PPVIS software.
inverter in normal operation
configuration.
Fan Life expired Fan used is too old. Check the expected lifetime of
the different fans of the
equipment, and replace them if
required.

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

7.11. RESERVE WARNING


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

RESERVE WARNINGS POSSIBLE CAUSES SOLUTIONS

Reserve Voltage NOK 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.
Res. Frequency NOK The reserve frequency is not correct Check the reserve frequency, try
to establish a correct reserve. No
action on the inverter.
Phase Sequence For three phase inverter, the phase Interchange two phases, to
sequence is not correct. reverse direction of phase
rotation
Reserve Inhibited Error of software configuration. Call engineer.
Paral. Res. Flt M. 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 POSSIBLE CAUSES SOLUTIONS


SWITCH FAULTS

Emerg. Power Off The AC load is no more supplied due Check the reason of the
to an Emergency power Off order sent volunteer Emergency Power Off
to the dedicated input. order.
S.S Overload Flt M. The reserve static switch has fed a too Reduce load. Reset this
high AC load for a too long time. memorized fault with the LCD
display inverter reset.
Inv. Stat Sw Flt M. The inverter static switch is in failure Check the wiring of the inverter
and is not correctly controlled. static switch and its associated
driver (both anti parallel SCRs
must be driven so as to have
positive and negative voltage on
the AC load).
After correction, reset this
memorized fault with the LCD
display inverter reset.

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If new occurrence, call engineer.


Res stat Sw Flt M. The reserve static switch is in failure Check the wiring of the reserve
and is not correctly controlled. static switch and its associated
driver (both anti parallel SCRs
must be driven so as to have
positive and negative voltage on
the AC load). After correction,
reset this memorized fault with
the LCD display inverter reset.
If new occurrence, call engineer.

Stat Sw H/W Flt M. Problem in the power supply of the Check the power supply of the
reserve static switch driver board. COGAS or CDCS boards.

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 POSSIBLE CAUSES SOLUTIONS


WARNINGS

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

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

8.1. GENERAL NOTES 66

8.1. GENERAL NOTES

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

− Careful choice of components


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

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

Page 66 of 68
CHLORIDE
INDUSTRIAL SYSTEMS

9. DRAWINGS

Title Page

9.1. GENERAL NOTES 67

9.1. GENERAL NOTES

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

Terminal identification. Terminals are identified on the schematic.

Drawing identification. The Chloride drawing prefixes identify the type of drawing

PA - General arrangement drawing PA-318107


SU - Single line diagram 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 05 06 07 08 09 10 11 12 13

0 TITLE PAGE xx xx xx xx xx
1 GENERAL ARRANGEMENT xx xx xx xx
2 CUBICLE FOOTPRINT DETAIL xx xx xx CUSTOMER : INDIAN OIL CORPORATION LTD., NEW DELHI
3 BOTTOM GLAND PLATE ARRANGEMENT xx
4 DISPLAY DETAIL PAGE 1 xx xx PROJECT : 2.2MTPA DHDT PLANT, VADODARA
5 DISPLAY DETAIL PAGE 2 xx xx
6 NAMEPLATE DETAIL xx XX xx EQUIPMENT : DUAL UPS Apodys 70kVA 370VDC 1x110VAC
7 BATTERY PROTECTION BOX xx

TAG NUMBER : 38 UPS-4-05 & 38 UPS-2-03

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: PA318107

CUST. : CHLORIDE INDUSTRIAL SYSTEMS

PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd

MFR. : CIS, CHASSIEU, FRANCE

GENERAL ARRANGEMENT
03/09/2009 MHS AS BUILT 04

29/07/2009 MCC UPDATED 03

01/04/2009 MHS INPUT LIGHTS ADDED 02


Indice/
16/03/2009 LML UPDATED FOLLOWING COMMENTS 01
Issue Page
07/11/2008 MHS FOR APPROVAL 00
PA318107 04 0
Date Creat. Verif. App. Description modif. Indice/Issue
Height : 1982 mm
Width : 4800 mm
Depth : 1008 mm =UPS1+A1 =BYP1+A2 =UPS2+A3
Protection : IP31
N
Paint : 631 as per IS:5 P
TAG A TAG B TAG C
1800mm
Lock : Retractable Handle P
Hz

Key : 1333 H1 H2 H3 H1 H2 H3 H1 H2 H3

Cable entry : BOTTOM

1982
OPERATING HEIGHT
OF THE SWITCHES

LABEL / TAG :

TAG A : UPS 1
TAG B : BYP 1

100
TAG C : UPS 2
300mm
=UPS1+A1 : UPS 1 CUBICLE
=BYP1+A2 : BYPASS CUBICLE 1180 kg 500 kg 1180 kg
=UPS2+A3 : UPS 2 CUBICLE 200 mini

CHARGER WALL
-H1 : CHARGER SUPPLY - PHASE 1 OK 1600 1200 1600
-H2 : CHARGER SUPPLY - PHASE 2 OK
-H3 : CHARGER SUPPLY - PHASE 3 OK
BYPASS
200 mini

-H1 : BYPASS SUPPLY - PHASE 1 OK


-H2 : BYPASS SUPPLY - PHASE 2 OK
1008

-H3 : BYPASS SUPPLY - PHASE 3 OK


282x120 282x120 282x120 282x120 182x120 282x120 282x120 282x120 282x120 282x120 282x120

SHIPPING BREAK
282x120 282x120 282x120 282x120 182x120 282x120 282x120 282x120 282x120 282x120 282x120

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
800

CIS FILE NO.: PA318107

CUST. : CHLORIDE INDUSTRIAL SYSTEMS

PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd

MFR. : CIS, CHASSIEU, FRANCE

GENERAL ARRANGEMENT Ind/Rev Page


30/07/2009 MCC UPDATED PA318107 03 1
Date Creat. Verif. App. Description modif.
1030 1430

315.0 715.0 715.0 715.0

1008

1008
830

830
1200 1600
92.5

92.5
Ø13 Ø13
100

100
72.5

72.5
72.5 62.5 62.5

J.REQ.NO: 18-3293-00/O.65/0223/OO
100 125
PROJ. NO: 18-3293

CIS FILE NO.: PA318107 CENTRAL FOOT


ANGLE FOOT DETAIL
CUST. : CHLORIDE INDUSTRIAL SYSTEMS DETAIL

PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd

MFR. : CIS, CHASSIEU, FRANCE

CUBICLE FOOTPRINT DETAIL Ind/Rev Page


01/04/2009 MHS INPUT LIGHTS ADDED PA318107 02 2
Date Creat. Verif. App. Description modif.
1200 1600
1008

1008
60

60
182x120 282x120 282x120 282x120 282x120 282x120 282x120

182x120 282x120 282x120 282x120 282x120 282x120 282x120


131

131
77 77 77
109.0 189 79.5 159

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: PA318107

CUST. : CHLORIDE INDUSTRIAL SYSTEMS

PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd

MFR. : CIS, CHASSIEU, FRANCE

BOTTOM GLAND PLATE ARRANGEMENT Ind/Rev Page


01/04/2009 MHS INPUT LIGHTS ADDED PA318107 02 3
Date Creat. Verif. App. Description modif.
STOP

Sync. C UPS

1 2 3
100%

100% 0

OK 0 1
Rectifier
0 1
Inverter

LED view LED colour Description Comments


UPS normal
Green /
operation
Green flashing Load on battery or on Loads powered by battery or
reserve reserve.
UPS One or more subassembly are
Orange
WARNING affected but not stopped.

UPS Subassembly are faulty and


Red
FAULT stopped or manually stopped.

STOP CAN communication The UPS communication CAN


Red flashing BUS is not correctly plugged or
FAULT
in failure.

Cancel audible alarm


(It cancels internal audible alarm until a new alarm occurs)

User switches used to control the Graphical Liquid Crystal Display:


J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
Select previous Cancel parameters
CIS FILE NO.: PA318107 Up in menus
C Back in menus
CUST. : CHLORIDE INDUSTRIAL SYSTEMS

PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat


Select next Valid parameters
CONSLT : Jacobs Engineering India Pvt Ltd Down in menus OK Enter in menus
MFR. : CIS, CHASSIEU, FRANCE

DISPLAY DETAIL PAGE 1 Ind/Rev Page


16/03/2009 LML UPDATED FOLLOWING COMMENTS PA318107 01 4
Date Creat. Verif. App. Description modif.
Rectifier information Inverter information
Status indications Measurements indications Status indications Measurements indications
Charger OFF Charger output DC voltage Inverter synchronised Inverter input DC voltage
Initialisation Charger output DC current Inverter on crystal Inverter ouput voltage (between phases and neutral)
Charger Stop Charger input voltage (between each phase)
Equalisation mode Charger input current (on each phase) Inverter not running Inverter frequency
Equalisation imposed Charger input frequency Inverter switched off Faults indications
Floating mode Number of mains failures No fault
Battery test mode
Battery test imposed Inverter switched off
Boost mode VCE bridge fault memorised
Warnings indications Inverter overload fault memorised
No warning Over-temperature fault memorised
Faults indications Warnings indications Commissioning Low DC voltage
No fault Test mode Software time-out Repeated low DC voltage memorised
High DC voltage DC voltage low Fan failure High DC voltage memorised
High DC voltage memorised Overload inhibit
Too high Ibattery memorised Charger in current limit Inverter overload warning Microcontroller fault memorised
Charger fuse blown High AC voltage memorised
Input protection open Frequency fault memorised
Charger off
Wrong phase sequence
AC supply fault
Reserve information
Battery information Warnings indications Measurements indications
No warning Reserve voltage (between phases and neutral)
Status indications Warnings indications Reserve voltage fault Reserve frequency
Normal DC earth fault Reserve frequency fault
Discharging Battery begin discharge Wrong phase sequence
Charging Status indications
Imminent shutdown No warning ; no fault
Fault or warning
Warning ; no fault
No warning ; fault
Warning + fault
Faults indications Measurements indications
No fault Battery voltage
Battery test fault memorised Battery current
Battery temperature
Load and static switch information
End of discharge
Battery protection open Battery autonomy (%) Status indications Measurements indications
Load on inverter Load voltage (between phases and neutral)
Load on reserve Load current (on each phase)
Manual bypass on Load frequency
REMOTE ALARM Load not supplied Load power (on each phase in kVA)
J.REQ.NO: 18-3293-00/O.65/0223/OO Load power (on each phase in kW)
Charger common alarm Faults indications Total time on inverter
PROJ. NO: 18-3293
UPS charger failure No fault Load current ratio (%)
CIS FILE NO.: PA318107 UPS inverter failure Static switch overload fault memorised Warnings indications
Battery discharged Inverter static switch fault memorised No warning
CUST. : CHLORIDE INDUSTRIAL SYSTEMS Battery isolated
Reserve static switch fault memorised Manual bypass closed
PROJ. : 2.2 MTPA DHDT PLANT Static switch hardware fault memorised Static switch overload
CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd


MFR. : CIS, CHASSIEU, FRANCE

DISPLAY DETAIL PAGE 2 Ind/Rev Page


16/03/2009 LML UPDATED FOLLOWING COMMENTS PA318107 01 5
Date Creat. Verif. App. Description modif.
Quantité/quantity : 1

Matière/material : Engraved plate

Epaisseur/thickness : 15/10ème

Couleur de fond/background 100mm


Blanc/White
colour :
5mm
Couleur de caractères/letters 4 x Ø 3.2
Noir/Black
colour :
Hauteur de caractères/letters
2mm

5mm
height : MANUFACTURER : CHLORIDE INDUSTRIAL SYSTEMS
30 av Montgolfier – 69680 CHASSIEU (France)
Police/letters type : SL513 ( Arial ) Tel : (+33) 4 78 40 13 56 Fax : (+33) 4 78 90 58 90
EQUIPMENT : DUAL UPS Apodys 70kVA 370VDC 1x110VAC

AC Input Voltage : 415V


Input Phases : 3
Input Frequency : 50Hz
DC Voltage : 370V
DC Current : 209.34A

100mm
Battery Type : CdNi
Number of Cells : 293
Capacity : 310Ah
Autonomy : 60mn
AC Output Voltage : 110V
Output Phases : 1
Output Frequency : 50Hz

Serial Number : L08-1262/L09-0831


Equipment tag number : 38UPS-4-05/38UPS-2-03

J.REQ.NO: 18-3293-00/O.65/0223/OO
Year of manufacture : 2008

PROJ. NO: 18-3293

CIS FILE NO.: PA318107

CUST. : CHLORIDE INDUSTRIAL SYSTEMS

PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd


MFR. : CIS, CHASSIEU, FRANCE

NAMEPLATE DETAIL Ind/Rev Page


29/07/2009 MCC UPDATED PA318107 03 6
Date Creat. Verif. App. Description modif.
Height : 1000 mm
Width : 800 mm
Depth : 400 mm
Protection : IP31
400mm 800mm
Paint : 631 as per IS:5
Cable entry : BOTTOM

1000mm

1045mm
960mm
LOCKING

4x
FASTENING Ø 9mm
760mm
845mm

BOTTOM
GLAND PLATE

12.5
310 x 96 310 x 96

35
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: PA318107

CUST. : CHLORIDE INDUSTRIAL SYSTEMS

PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd

MFR. : CIS, CHASSIEU, FRANCE

BATTERY PROTECTION BOX Ind/Rev Page


16/03/09 LML UPDATED FOLLOWING COMMENTS PA318107 01 7
Date Creat. Verif. App. Description modif.
Page Titre/Title 00 01 02 03 04 05 06 07 08 09 10 11 12 13

0 TITLE PAGE xx xx xx xx xx
1 SINGLE LINE DIAGRAM xx xx xx xx
CUSTOMER : INDIAN OIL CORPORATION LTD., NEW DELHI

PROJECT : 2.2MTPA DHDT PLANT, VADODARA

EQUIPMENT : DUAL UPS Apodys 70kVA 370VDC 1x110VAC

TAG NUMBER : 38 UPS-4-05 & 38 UPS-2-03

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: SU318107

CUST. : CHLORIDE INDUSTRIAL SYSTEMS


PROJ. : 2.2 MTPA DHDT PLANT

CLIENT : IOCL Vododara, Gujarat

CONSLT : Jacobs Engineering India Pvt Ltd

MFR. : CIS, CHASSIEU, FRANCE

SINGLE LINE DIAGRAM

03/09/2009 MHS AS BUILT 04

30/07/2009 MCC UPDATED 03

01/04/2009 MHS INPUT LIGHTS ADDED 02


Indice/
16/03/2009 LML UPDATED FOLLOWING COMMENTS 01
Issue Page
07/11/2008 MHS FOR APPROVAL 00
SU318107 04 0
Date Creat. Verif. App. Description modif. Indice/Issue
=BYP1+A2
H1-H2-H3 -T31
-U31
70kVA
X 2Ph/415VAC -1Ph/110VAC
100kVA
110VAC +/-1%
50Hz
-Q31
BYPASS SUPPLY
(200A)
TPN / 415VAC +/-10%
50Hz
Terminals Cu 50x5

=UPS1+A1 APODYS
H1-H2-H3 DISPLAY
U, I, F U, I U INVERTER 1 70kVA U, F
X CHARGER 1
370VDC/147-208A
1Ph/110VAC
50Hz
U -V18
AC SUPPLY 1 -Q3 -V2 -Q2 -Q26
TPN / 415VAC +/-10% (200A) (250A) (250A) (800A)
50Hz
Terminals Cu 50x5

K100

BATTERY 1 370VDC =BAT1+A4


Type : NiCd
I
Reference : KBM 277
Number of Cells : 293 -Q5_1
Capacity : 277h (250A)
Autonomy : 60min * (P40)
* (P40)
U, F
BATTERY 2 370VDC -Q4
Type : NiCd (250A) -Q22
Reference : KMB277 -V21 (800A)
U, F
Number of Cells : 293 -Q5_2
Capacity : 277Ah (250A)
-Q21
Autonomy : 60min * (P40)
* (P40)
U, F, I, W
-Q23 (800A) AC LOAD
I (800A) 1Ph / 110VAC
K100
Float : 1.41V/cell 50Hz
Charge : 1.65V/cell U, F, I, W Cu 50x5
Manu. Boost : 1.70V/cell
End of Disch.: 1.00V/cell =UPS2+A3 NEUTRAL TO EARTH
APODYS -Q 21 22 23

H1-H2-H3 DISPLAY U, F
AUTO XX
U, I, F U, I U INVERTER 2 70kVA TRANSITION X XX
X CHARGER 2 1Ph/110VAC TEST XX
370VDC/147-208A 50Hz
-Q3 -V2 -Q2
U -V18 -Q27
MAINTENANCE X
AC SUPPLY 2
TPN / 415VAC +/-10% (200A) (250A) (250A) (800A)
50Hz
Terminals Cu 50x5

-T31 : BYPASS TRANSFORMER -Q2 : CHARGER OUTPUT ISOLATOR =UPS1+A1 : UPS 1 CUBICLE
-U31 : STABILISER -Q3 : CHARGER INPUT FUSE SWITCH =BYP1+A2 : BYPASS CUBICLE
-V2 : CHARGER OUTPUT BLOCKING DIODE -Q5-1 & 2 : BATTERY CIRCUIT BREAKER =UPS2+A3 : UPS 2 CUBICLE
-V18/V21 : STATIC SWITCH -Q21 : BYPASS SWITCH =BAT1+A4 : BATTERY PROTECTION BOX
SIZE OF TERMINALS -K100 : DC EARTH FAULT -Q26 : INVERTER 1 OUTPUT ISOLATOR
P6 : 0.14 to 4 mm² -Q27 : INVERTER 2 OUTPUT ISOLATOR
J.REQ.NO: 18-3293-00/O.65/0223/OO P8 : 0.2 to 6 mm² -Q31 : BYPASS INPUT FUSE SWITCH
P10 : 0.5 to 10 mm² -H3 : CHARGER SUPPLY ON
PROJ. NO: 18-3293
P12 :1.5 to 16 mm²
CIS FILE NO.: SU318107 P16 : 1.5 to 35 mm²
P32 (M10) : 25 to 50 mm²
CUST. : CHLORIDE INDUSTRIAL SYSTEMS
P40 (M12) : 35 to 95 mm²
PROJ. : 2.2 MTPA DHDT PLANT P46 (M12) : 50 to 150 mm²
P53 (M16) : 70 to 240 mm²
CLIENT : IOCL Vododara, Gujarat
Cu Busbars: Copper busbars INTERCONNECTION CABLES
CONSLT : Jacobs Engineering India Pvt Ltd
* NOT SUPPLIED BY CHLORIDE
MFR. : CIS, CHASSIEU, FRANCE

SINGLE LINE DIAGRAM Ind/Rev Page


30/07/2009 MCC UPDATED SU318107 03 1
Date Creat. Verif. App. DESCRIPTION
CHLORIDE
INDUSTRIAL SYSTEMS

10. ATTACHMENTS
Title Page

10. ATTACHMENTS 68

10.1. battery manual 68

10.1. BATTERY MANUAL

Page 68 of 68
NCPP
Nickel Cadmium Pocket Plate

Operation and Service manual


CONTENTS

1.0 TECHNICAL SPECIFICATION 1

2.0 INTRODUCTION 2

3.0 SAFETY PRECAUTIONS 4

4.0 RECEIVING THE SHIPMENT 5

5.0 STORAGE 6

6.0 INSTALLATION 8

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 DO’S AND DO NOT’S 21

13.0 DM/ DI WATER SPECIFICATION 23

14.0 SERVICE LOG 24 -25

15.0 TOOLS & ACCESSORIES 26

16.0 DRAWINGS 27

1
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:

Charge
2 Ni(OH)2 + Cd(OH)2 ⇔ 2 NiOOH + Cd + 2H2O
Discharge

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 doesn’t 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.

2
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
3.0 SAFETY PRECAUTIONS

3.1 ELECTROLYTE

The alkaline electrolyte (solution of potassium hydroxide in DM/DI water) is a strong


caustic agent. Wear rubber gloves, eye protection and long sleeved clothing when
working on the battery. Before working with electrolyte, make sure that water for
washing is easily available. If electrolyte is splashed on the skin or clothing, wash
immediately with water for 10 to 15 minutes. If eyes are affected, flood with water
followed by eye wash solution and obtain immediate medical attention.

3.2 KEEP FLAMES AWAY

The battery will produce a mixture of oxygen and hydrogen gases during the last
portion of high rate charging.

Do not adjust connections etc., while charging or in the first hour after charging.

Discharge any possible static electricity from clothes by touching earth connected
part.
Do not smoke in the battery room.
Keep the battery location well ventilated to prevent buildup of the oxygen and
hydrogen gases, and do not cover the battery during charging.

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.

4
4.0 RECEIVING THE SHIPMENT

4.1 UNPACKING AND INSPECTION

Do not over-turn the packages.

Unpack the batteries immediately upon the arrival and inspect for possible damage
in shipment.

Make sure that small packages are not thrown out together with the packing
material.

Check that all the material listed in the packing list has been received.

PLEASE INFORM HBL NIFE IMMEDIATELY IN CASE OF ANY DAMAGE OR


SHORTAGES IN THE CONSIGNMENT.

4.2 SHIPPING METHOD I

THE BATTERY SHIPPED IN FILLED AND CHARGED CONDITION

Remove immediately the transport seal (red plastic film) from the vent cap. Remove
the transit cap (blue/red), wherever mounted on cell terminals for big size cells.

Check the electrolyte level in the cells and add electrolyte if necessary.

The battery is then ready for installation or storing.

THE BATTERY MUST NEVER BE CHARGED WITH THE TRANSPORT SEAL IN


PLACE AS THIS CAN CAUSE PERMANENT DAMAGE.

4.3 SHIPPING METHOD II

THE BATTERY SHIPPED IN DISCHARGED AND EMPTY CONDITION

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
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 STORAGE OF USED BATTERY IN DRY & DISCHARGED CONDITION
If the storage period is to exceed one year, the batteries should be fully discharged
at 0.2 C5 Amps, to an end voltage 0.6 volts per cell, and the electrolyte fully drained
by inverting the batteries for about 5 minutes. Use a plastic film to seal the flip top
vent.

Clean the battery thoroughly, 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 of the battery.

Store the electrolyte in clean, air–tight plastic containers for future use. After
removing the battery from storage, follow the instructions for electrolyte filling, first
charging and installing the battery.

7
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 MOUNTING AND CONNECTIONS


HBL NIFE battery racks are recommended for proper installation.
These racks are made of steel components, which are protected with alkali-resistant
paint. The step construction of the racks permit visual electrolyte level checks to be
made on all cells and greatly facilitates the maintenance activity of topping up with
demineralized water.
Battery racks are available in 2,3, or 4 steps in one or two tier configurations. Racks
can be positioned alongside each other or back to back to suit the available space in
the battery location. Ensure that the floor is level while positioning the racks.

8
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 inter-
cell 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:

BOLT DIAMETER RECOMMENDED TORQUE

M 5 7.5 Nm (0.75 kgfm)


M 8 20 Nm (2.0 kgfm)
M 10 30 Nm (3.0 kgfm)

Ensure correct torque by using an appropriate torque wrench.

Improper torque will affect battery performance.

It is important that the battery is mounted firmly.

When there is a risk of crate movement as in the case of mobile applications, use
wooden or plastic wedges for arresting the movement.

9
7.0 ELECTROLYTE PREPARATION FOR FIRST FILLING

Please read and follow the safety precautions carefully while preparing the electrolyte.

The quantity of Electrolyte (if supplied in liquid form) per cell is given in the Technical
Specifications.

The quantities of solid lithium hydroxide or solid potassium hydroxide required for each
Battery, if supplied in dry & discharged condition are given in separate sheet. Use this
data as proportions for preparing the electrolyte.

1000 cc Type B electrolyte contains the following quantities of potassium hydroxide,


lithium hydroxide and DM/DI water.

Electrolyte Potassium Lithium Demineralised Cell Type


Type Hydroxide Hydroxide Water
(88-90%) (55%)

B-22, Density 268 gms. 40 gms. 890 cc Standard


1.20

B-30, 384 gms. 54 gms. 840 cc For special


Density1.28 Application(solar)

Type ‘B’ Electrolyte is a solution of lithium hydroxide crystals and potassium hydroxide
flakes in DM/DI water. The number following the ‘B’ represents the quantity of lithium
hydroxide in grams (assuming 100% assay) per litre of electrolyte.

The required quantity of D.M. Water is first into the container and appropriate quantity
of lithium hydroxide crystals are added with constant stirring. When all the lithium
hydroxide has dissolved, potassium hydroxide flakes are slowly added with constant
stirring. The solution will become hot.

After cooling to room temperature, adjust the density as required within a tolerance of
+/-0.01 by adding D.M. Water.

7.1 APPARATUS

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
9.2.0 ROUTINE CHARGING (DURING USAGE)

During regular usage the charging method and parameters are to be determined by
charger, load and battery to ensure the system compatibility.

9.2.1 SEPARATE CHARGING

When the battery is being charged separate from its load, we recommend charging
for 8 hours with a current for 0.2 C5 Amps, to recharge a fully discharged battery to
full state of charge.

A lower charging current can be applied for a proportionally longer time, however the
current should not be less than 0.1 C5 A for H cells and 0.05 C5 A for M and L cells.

Constant voltage charging can be used but it requires longer recharge time. The
charging parameters are as per high rate charging under clause 9.2.3

9.2.2 PARALLEL OPERATION

For continuous parallel operation with occasional battery discharge, use a float-
charging voltage in the range of 1.40 to 1.42 volts per cell.

9.2.3 HIGH RATE CHARGING

For recuperative charging of the battery after a discharge, adjust the charging volt-
ages to a level corresponding to:

1-53 – 1.67V/Cell for H cells

1.54 – 1.69 V/Cell for M cells and

1.55 – 1.70 / Cell for L cells

charging current limit should be within 0.1 to 0.2 C5

9.2.4 OVER CHARGING

Over charging within reasonable limits will not damage the battery, but water
consumption will be increased.

9.2.5 UNDER CHARGING

A Ni-Cd battery can be left standing for short periods at any state of charge without
damage.

But continuous undercharging combined with deep discharging will affect the battery
life.

Note : If the battery is continuously on float charge, it is recommended to boost charge


once in every 6 months to make sure that the state of charge is at top. The boost
charging should be for 8 hours.

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 NEVER USE SULPHRIC ACID


Sulphuric acid will ruin the alkaline battery.
Filling bottles, hydrometers etc., used with lead acid batteries must never be used
with alkaline batteries in order to prevent acid contamination.

14
10.6 SPECIFIC GRAVITY

The electrolyte specific gravity should be as mentioned in technical specifications.

The specific gravity is not influenced by the state of charge, but increases slightly
when the electrolyte level is lowered due to water loss.

Electrolyte specific gravity should not be measured immediately after water has been
added.

10.7 CHECKING THE CHARGING

In parallel operation it is great importance that the recommended charging voltage is kept
unchanged. The charger should be checked at least once a year.

High water consumption of the battery is usually caused by a high float voltage setting of the
charger, which give higher current than required during float operation.

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. SYMPTOM PROBABLE CAUSE RECOMMENDED CORRECTIVE


ACTION
01. Erratic charger Wrong polarity of cell, Check each cell or block for correct
behaviour block, row of battery. polarity.

Interruption at Check that no connector or cable is


connector missing and that all connections are
tight and cables securely fastened in
cable lugs.

Interruption due to Check if the cell is empty because of


empty cell leakage. If so, remove or short circuit
the cell and use the battery with one
cell less, until replacement is made. If
the cell is part of the block, do not
remove the block, just short circuit the
cell.

If the battery is filled with electrolyte


on site it could be that one cell has
been forgotten. If so, disconnect the
cell and fill it with electrolyte.

Faulty charger See charger instructions for


troubleshooting.

15
S.No. SYMPTOM PROBABLE CAUSE RECOMMENDED CORRECTIVE
ACTION
02. Earth fault Small leak or leaks Check for wetness on battery stand,
indication or with a voltmeter, area of the battery
having the lowest potential to ground.
See (1) for procedure if a cell is
leaking.
Battery wet due to Disconnect few connectors to avoid
overfilling high or over boiling voltage and clean
the battery. See (8).
Other equipment of Isolate various parts of the DC system
system to find the fault.
03. Continuous Charging voltage is See charger instructions for
heavy gassing above the information on charging mode and
recommended float settings.
voltage .
04. No power or Interruption at See SL.No: 1.
capacity at all connector

Interruption due to See SL.No: 1.


empty cell
Battery completely Determine why the battery is
discharged. discharged. The reason could be
faulty charger or fuse, wrong float
voltage or interruption in the battery.
Recharge the battery according to
instructions.
05. Too short Too larger load. The load may be larger that what the
discharge time. battery was intended for. Check the
The voltage discharge against battery
decreases performance data. Note that the rated
quickly at the number of ampere hours can only be
end. delivered at discharges, of 5 hours or
longer. For short discharges,
batteries will give higher currents but
less ampere-hour.
Insufficient charging. Determine why the battery is not
charged to a correct level. The
reason could be low float voltage, no
high-rate recharge after previous
heavy discharge, too short high-rate
recharge, of high-rate recharge to
voltage that is too low. Recharge the
battery as per instructions and
discharge again.
Too low battery If the same result is achieved after full
capacity. and complete charging, the battery
capacity is low. It may still be able to
work its application, especially if it is
high-rate discharges such as in
switchgear operation or engine
starting. The reason for low capacity
could be age, heavy use, insufficient
charging or unsuitable storage.

16
S.No. SYMPTOM PROBABLE CAUSE RECOMMENDED CORRECTIVE
ACTION
06. Low discharge Very low voltage for Check the individual cell voltages during
voltage during a one or few cells. discharge and full recharge. If the
major part of voltage of an individual cell does not
discharge. 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.
Battery designed with This condition sometimes occurs if the
high cell end voltage. design cell end voltage is 1.14 – 1.18
The discharge volt per cell and the battery has been in
preceded by long term service for sometime. It does not mean
float charge without that the capacity has decreased. It is
discharge. 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.
07 Too low for Discharged battery Insufficient charging, See(06)
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.
08 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 Batteries are often divided in two


halves, which is good from reliability
and maintenance viewpoints. If each
half has a separate charger and the
voltage is different, the electrolyte
levels in the two halves will be
different

Leaking cell If one cell has a lower electrolyte level


than all the others, it is probably
leaking. The leak could be small and
difficult to find, but the battery stand is
probably wet from electrolyte under
the cell. One individual cell could not
consume more water than the others
as the same current goes through all
cells.
Short circuit in one A cell with partial or complete short
cell circuit will consume less water than
the others. Let the cell remain until
replacement is arranged.

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 ELECTROLYTE TYPE ELECTROLYTE TYPE ELECTROLYTE TYPE


FOR FIRST FILLING FOR REPALCEMENT FOR COMMISSIONING
IF SUPPLIED DRY

Standard B-22, Density 1.20 B-5, Density 1.19 B22, Density 1.20

Special Application B-30, Density 1.28 B-12, Density 1.25 B30, Density 1.28
(Solar)

11.1 PREPARATION OF ELECTROLYTE

1000 cc Type B electrolyte contains the following quantities of potassium hydroxide,


lithium hydroxide and DM/DI water.

ELECTROLYTE POTASSIUM LITHIUM DM/DI


TYPE FOR HYDROXIDE HYDROXIDE WATER
REPLACEMENT (88-89%) (55%)

B-5, Density 1.19 276 gms.. 9 gms. 910 cc.

B-12, Density 1.25 363 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
density after filling.

Never let cells remain empty if they are not entirely discharged as this can cause
permanent damage.

It is not advisable to pour the used electrolyte into the sink. Follow norms for
chemical waste disposal, which are valid in your area.

11.4 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
12.0 DO’S AND DO NOT’S

12.1 DO’S

1. Keep the battery always dry and clean. This will prevent leakage of current and
protect the nickel plating on the external battery components.

2. Check inter-cell connectors for proper tightness. This will prevent heat
generation at the point of loose contact, which causes damage to the
components and can be a fire hazard. Loose contact can also cause battery
failure due to creation of an open circuit.

3. Ensure that the cell connections have been made as per the wiring diagram
provided. Normally Red washer on cell terminal indicates positive polarity and
blue washer indicates negative polarity.

4. Ensure that the battery cable lugs are electro plated. This will prevent the
copper from reacting with the electrolyte.

5. Ensure that the transport seal (plastic strip in vent cap) is removed before
charging. This will permit escape of the oxygen and hydrogen gases generated
during charging.

6. Keep vent caps always closed during charging and discharging. This will
prevent the carbon dioxide from the air from combining with the alkaline
electrolyte and producing potassium carbonate, thereby reducing the electrical
conductivity of the electrolyte.

7. Check the electrolyte level and ensure that it does not fall below the minimum
level, which is indicated, on the cell-marking label. This active material
contained in the portion of the plates, which are exposed above the Electrolyte,
will be permanently damaged if the battery remains in service.

8. Use only DM/DI water to top up the cells. (During initial Commissioning use
only electrolyte to make up for loss of electrolyte during transportation). Only
DM/DI water is to be used to compensate for the loss of water during charging,
and maintain the required electrolyte level and specific gravity.

9. Ensure proper functioning of charger and proper connections to the battery.


Correct voltage and current settings are important for keeping the battery in
charged, ready to use condition.

10. Use insulated tools while working on the battery to prevent accidental short
circuit and consequent damage.

11. Use alkaline electrolyte only since this is an alkaline battery.

21
12.2 DO NOT’S

1. Do not use apparatus, like hydrometers, capillary tubes, and thermometers


etc., used in lead acid batteries in order to prevent contamination of electrolyte.

2. Do not use petrol, kerosene, or any strong chemicals for cleaning batteries.

3. Do not use wire or any hard brush to clean deposits on the intercell connectors
and terminals since this will damage the nickel plating.

4. Do not use aluminum cables for making connections to the battery terminals
since aluminum reacts with the alkaline electrolyte.

5. Do not keep vent caps open and expose electrolyte to air, since this will cause
some of the electrolyte to be converted to potassium carbonate and thereby
reduce the conductivity of the electrolyte.

6. Do not spill water or electrolyte on and around the battery since this will create
conductive paths leading to leakage of current.

7. Do not measure specific gravity immediately after adding DM/DI water since
this will indicate a lower specific gravity due to inadequate mixing of the water
with electrolyte in the cell. Specific gravity can be measured after one hour.

8. Do not install the Battery in places where it is exposed to sunlight, since this
will cause accelerated ageing of plastic components due to ultra violet
radiation.

9. Do not remove vent caps (in case of flip type vent caps) for topping up since
frequent removal can damage the vent cap and the cell lid. In case of flip type
vent caps, gently press the cap to open the spring loaded vent lid and in case
of threaded type vent cap, gently unscrew the vent cap lid.

10. Do not use acid since the battery requires alkaline electrolyte. Addition of acid
will cause it to react with the alkaline electrolyte, and cause permanent battery
damage.

11. Do not charge the battery without removing the transport seal from the vent, or
while the battery is covered, since it is important to ventilate the battery and
permit the gases produced towards the end of charge to escape.

12. Do not adjust terminal connections during usage to prevent sparking which
can ignite the oxygen and hydrogen gases which are given off by the battery
towards completion of charge, and cause a fire / explosion.

13. Do not smoke in the battery room since it is a fire hazard.

14. Do not keep Batteries in the same room where acid batteries are kept.

22
13.0 DM / DI WATER SPECIFICATION

13.1 PERMITTED IMPURITIES IN WATER

IMPURITY CALCULATED AS TOPPING UP WATER FOR


WATER MAXIMUM PREPARATION OF
g/l 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 & CaO+MgO Traces Traces


Magnesium

Heavy Metals Traces 0.03

Evaporation 0.05 0.15

Organic KMNO4 0.03 0.06


impurities

Note : Topping up must be with DM/DI water with the conductivity less than 10 micro
siemens /cm

23
14.0 SERVICE LOG

Date of installation and commissioning: _________________________________

Battery No.: ___________________________

Date : _______________________________

CELL NOS DISCREPANCIES NOTICED CORRECTIVE ACTIONS / REMARKS

24
Service Log (Continue)

Date: _________________________

CELL NOS DISCREPANCIES NOTICED CORRECTIVE ACTIONS / REMARKS

25
15.0 TOOLS & ACCESSORIES

26
16.0 DRAWINGS

27
Corp.Mktg/12-2003/NCPP/O&S

HBL NIFE Power Systems Limited


Road # 10, Banjara Hills, Hyderabad - 500 034. INDIA
E-mail: contact@hblnife.com
www.hblnife.com